Sr. Process Engineer

AESC US; Columbia (SC); On-site; USD 110,000 - 150,000; Full time

Job summary

AESC US is seeking a Senior Process Engineer in Columbia, SC to own repack process cells, drive improvements, and mentor junior engineers. The role blends engineering rigor with production realities to optimize cycle time, quality, and profitability.

You will lead cross-functional projects, manage equipment and tooling, and ensure compliance with IATF 16949 and related standards while growing toward formal engineering management responsibilities as the operation scales.

Qualifications

• 7+ years of process engineering experience in high-volume manufacturing.
• Experience in repack, kitting, rework, or value-added operations preferred.
• Bachelor’s degree required.

Responsibilities

• Own end-to-end repack work cell processes including disassembly, inspection, rework, repackaging, and labeling.
• Lead root cause investigations (8D, RCA, FMEA) and implement corrective actions.
• Manage capital equipment projects, tooling, and production readiness.
• Develop process control plans and work instructions for operator training.
• Lead continuous improvement initiatives and Kaizen events.
• Support new program introductions and process transfers.
• Ensure safety and regulatory compliance across engineering activities.
• Lead cross-functional teams and mentor junior engineers.
• Analyze data to monitor stability, throughput, and costs.
• Prepare updates for plant leadership and stakeholders.
• Complete other duties as assigned.

Skills

Structured problem solving

Cross-functional collaboration

Project leadership

Data analysis

DOE / FMEA

Communication

Education

Bachelor’s degree in Industrial, Electrical, Mechanical, or Chemical Engineering

Tools

AutoCAD

Inventor

MS Office

Job description

Job Description

AESC is looking to add a Senior Process Engineer to our team in Columbia, SC.

Description & Requirements

About AESC US LLC

AESC is a global leader in the development and manufacturing of high-performance batteries for zero-emission electric vehicles and energy storage systems. Founded in Japan in 2007 and headquartered in Yokohama, AESC has been building manufacturing capabilities around the world in the U.S., U.K., Europe, Japan and China to serve key markets and leading customers locally for over 14 years. Today, AESC has become the partner of choice for the world’s leading OEMs and energy storage providers in North America, Europe, and Asia. Its advanced technology powers over one million electric vehicles and provides more than 15GWh of installed capacity for battery energy systems in over 60 countries. AESC is expanding its footprint in the United States with gigafactories in Kentucky, South Carolina, and Tennessee to meet the growing demand for EV and BESS batteries and strengthen its presence in the North American market. AESC's Tennessee gigafactory in Smyrna, which has been operational and supplying electric vehicle batteries for the Nissan LEAF since 2012, was retooled in 2025 and now produces batteries for Energy Storage Systems. The South Carolina gigafactory in Florence will supply next generation cells for BMW starting in 2026. The Kentucky gigafactory in Bowling Green will supply high-performance batteries and components for other OEMs. AESC is committed to our local communities where it is making its investments, creating jobs, and supporting local charities.

About the Role

The Senior Process Engineer is the technical lead for AESC’s repack operation, responsible for designing, stabilizing, and continuously improving the processes that support battery module inspection, rework, repackaging, and outbound fulfillment. This role sits at the intersection of engineering rigor and production reality — where process discipline, material flow, traceability, and cycle time efficiency are directly tied to customer commitments and site profitability. Beyond the technical scope, this position is structured for an engineer with the ambition and capability to grow into engineering management. The Senior Process Engineer will mentor junior engineers and technicians, lead cross-functional initiatives, and build the leadership presence and operational judgment that form the foundation for formal management responsibilities as the operation scales.

What You Will Do

• Process Ownership & Optimization: Own the end-to-end process for assigned repack work cells, including disassembly, inspection, rework, repackaging, labeling, and kitting; define and maintain control parameters, monitor throughput and quality KPIs, and drive sustained improvements in cycle time, first-pass yield, and material utilization.
• Technical Troubleshooting & Problem Solving: Lead root cause investigations for process escapes, rework defects, material handling failures, and quality deviations using structured methodologies (8D, RCA, FMEA); develop corrective and preventive actions and track effectiveness through sustained performance metrics.
• Equipment, Tooling & Fixture Management: Lead engineering scope for repack-specific capital investments, including material handling equipment, inspection fixtures, test stations, and packaging machinery; manage vendor qualification, FAT/SAT sign-off, and production readiness from procurement through steady-state operation.
• Engineering Standards & Documentation: Develop and maintain process control plans, work instructions, PFMEAs, and visual standards for repack work cells; ensure documentation is current, accurate, and written at a level that supports operator training and audit readiness under IATF 16949 and customer-specific requirements.
• Continuous Improvement Leadership: Identify and lead Kaizen events, line balancing exercises, and waste reduction initiatives focused on repack-specific losses ‑ including excessive rework loops, material handling inefficiencies, and packaging variation; mentor junior engineers and technicians through improvement projects while building sustainable team capability.
• New Program Introductions & Process Transfers: Lead process engineering activities for new repack SKUs, customer program launches, and inbound product transitions; develop work cell layouts, time studies, and operator qualification plans that enable rapid, repeatable ramp‑up with minimal quality risk.
• Safety & Regulatory Compliance: Champion a culture of safety within the engineering team and on the plant floor; conduct process and safety audits, ensure engineering changes comply with applicable standards (IATF 16949, ISO 14001, OSHA), and actively participate in risk assessments for new processes and equipment.
• Cross‑Functional & Team Leadership: Act as the engineering lead on cross‑functional project teams, providing direction to contractors, technicians, and junior engineers; model collaborative problem‑solving, set clear priorities, and develop the technical and professional skills of those around you as a precursor to formal people management responsibilities.
• Data Analysis & Process Control: Use SPC, time studies, and line efficiency data to monitor repack process stability, identify variation sources, and validate improvement actions; build reporting that gives operations leadership clear, actionable visibility into cost‑per‑unit, rework rates, and throughput trends.
• Stakeholder Communication & Reporting: Prepare and present engineering updates, project status, and improvement results to plant leadership and senior management; communicate technical findings in a clear, structured manner that supports decision‑making and builds confidence in the engineering team’s execution.
• Complete other duties as assigned.

What You Need

• Education: Bachelor’s degree in Industrial, Electrical, Mechanical, or Chemical Engineering.
• Experience: 7+ years of process engineering experience in a high-volume manufacturing or distribution/fulfillment environment, with direct ownership of production processes, quality systems, and continuous improvement initiatives; experience in repack, kitting, rework, or value‑added operations is strongly preferred.

Skills

• Demonstrated mastery of structured problem‑solving methodologies (8D, RCA, FMEA, DOE) with a track record of resolving chronic process issues and sustaining results; ability to coach others through these frameworks.
• Proficient in Microsoft Office applications, AutoCAD, and Inventor.
• Proven ability to manage multiple concurrent engineering projects from initiation through close, including capital equipment commissioning, new product introduction, and process improvement initiatives; comfortable setting priorities and holding timelines in a fast-paced environment.
• Familiarity with battery module or pack handling, storage requirements, and safety protocols is an advantage; candidates from adjacent industries involving high‑mix, low‑volume, or inspection‑intensive operations are also well‑positioned for this role.
• Self‑directed and highly organized, with the ability to manage competing priorities independently while keeping cross‑functional stakeholders informed; demonstrated willingness to take ownership and drive closure without waiting for direction.
• Experience managing contractors, suppliers, and external engineering resources through the full project lifecycle, from RFP and vendor selection through commissioning and production start‑up.
• Strong communicator with the confidence to present technical findings and recommendations to senior leadership; able to adapt style for operators, engineers, and executives alike, and to influence decisions without direct authority.
• Proficient in Microsoft Office (Excel, PowerPoint), AutoCAD, and data reporting tools; experience building dashboards or structured reporting that plant leadership can act on.
• Experience standing up or significantly restructuring a repack, rework, or value‑added operation, including developing work cell layouts, labor standards, and process documentation from early stages; comfort building structure in environments where processes are still being defined.
• Demonstrated ability to lead through influence in cross‑functional settings and an expressed interest in growing into engineering management; candidates who have informally mentored peers, led project teams, or taken on coordination responsibilities are encouraged to highlight that experience.
• Understands and follows all standards of IATF 16949 and VDA 6.3 quality standards. (Training and awareness will be provided for those who are not familiar with these standards)
• Understands and follows all standards of ISO 14001 environmental standards. (Training and awareness will be provided for those who are not familiar with these standards)
• Understands and follows all standards of IATF16949 and VDA 6.3 quality standards. (training and awareness will be provided for those who are not familiar with these standards)
• Understands and follows all standards of ISO14001 environmental standards. (training and awareness will be provided for those who are not familiar with these standards)

What is “Nice to Have”?

• People Leadership Trajectory: Prior experience formally or informally leading other engineers, technicians, or project teams; a clear interest in growing into an engineering management role and the self‑awareness to articulate what that path looks like for you.
• Greenfield/Brownfield Start‑Up Experience: Hands‑on involvement in new plant construction, retooling, or capacity expansion, with a working understanding of how to build and stabilize processes in environments where systems and standards are still maturing.
• Project Management Certification: PMP or equivalent; or demonstrated application of formal project management methodology on capital or NPI programs.
• Lean Six Sigma Certification: Green Belt or Black Belt, with applied project experience; candidates who have led kaizen events or VSM initiatives in a production environment are particularly well‑positioned.
• Battery or EV Supply Chain Background: Exposure to lithium‑ion battery handling, warehouse management systems (WMS), serialization/traceability requirements, or OEM‑driven packaging standards within an automotive or energy storage supply chain.
• Advanced Quality Tools: Working proficiency in PFMEA, Control Plans, MSA, and DOE; experience applying these tools in a production launch or process validation context rather than purely in a design or quality assurance role.
• Bilingual Proficiency: Japanese, Mandarin, or Spanish language skills are a plus given the global nature of AESC’s operations and supplier base.

Travel

Occasional domestic and international travel required.

What We Offer

Welcome to AESC, where you'll have the opportunity to tackle the world's most fascinating challenges alongside exceptionally