Process Development Engineer - Battery

Process Development Engineer - Battery - Boston, MA Area

We're looking for a Process Development Engineer - Battery who can turn cutting-edge R&D into reliable, production-ready manufacturing. In this role, you’ll work closely with Engineering and Operations to translate new processes into clear, repeatable procedures that support next generation thermal interface materials. You’ll own the details of process control and data analysis, implementing rigorous monitoring to spot patterns, uncover root causes, and push systems to meet high safety, capacity, and yield targets.

• Deliver key Release-to-Manufacturing milestones and capacity scaling across new manufacturing and quality processes.
• Audit, analyze and improve production processes to maximize yield, capacity and availability.
• Perform root cause analysis and resolution of assignable cause variation.
• Identify metrology needs to ensure processes remain in control. Implement data analysis, reporting and alerting schemes for swift detection and resolution of process deviations.
• Assist operations team in devising and implementing workflow improvements.
• Work with quality engineers to establish quality metrics that assure product form, fit and function.
• Lead process FMEA for new processes.
• Conspicuously exemplify high standards of safety, organization, communication and documentation.
• Implement 5S for production equipment and workstations.
• Interface with manufacturing, process, and quality control machinery to implement automated plant-level data acquisition and optimization. Experience with SCADA software a plus.
• Work effectively in a startup or small company setting. Embrace challenges, adapt to changes, and continuously seek to improve processes and methods.

• Demonstrated success developing chemical processes, roll-to-roll systems, and other continuous manufacturing workflows.
• Hands-on ability to perform hazard analyses, define engineering controls, and ensure safe operation of complex processes.
• Experience applying human factors engineering to improve usability, safety, and operator efficiency.
• Skilled with CNC machining, along with common power tools and hand tools used in machine build and process development.
• Proficiency in mechanical design using Solid Works or similar CAD platforms.
• Strong understanding of sensing technologies and data acquisition methods for process monitoring and control.
• Practical experience applying statistical process control to maintain stability and reduce variation.
• Commitment to 5S principles and building clean, organized, efficient work areas.
• Consistent track record of driving continuous improvement initiatives that raise throughput, quality, and reliability.
• Ability to perform process FMEAs to identify risks, prioritize mitigations, and strengthen process robustness.
• Experience creating and maintaining visual management systems that support clear communication and fast decision-making.
• Solid grounding in applied statistics, including capability analysis, control charts, ANOVA, and hypothesis testing.