Senior Manufacturing Engineer

Senior Manufacturing Engineer

Ener Sys Advanced Systems (EAS) is a specialized division of Ener Sys—a global leader in stored energy solutions for industrial applications. EAS focuses on cutting-edge energy solutions for the aerospace, defense, and medical industries. As we continue to grow, we're looking for individuals who share a passion for these industries and want to be part of an innovative, dynamic team.

Compensation Range: $110,000 to $130,000 per year. Compensation may vary based on applicant's work experience, education level, skill set.

Job Purpose:

The Senior Manufacturing Engineer at Bren-Tronics, part of Ener Sys and manufacture of advanced power solutions, is a key technical leader responsible for developing, optimizing, and sustaining manufacturing processes for battery production in a defense environment. This role focuses on driving operational excellence through advanced failure analysis, continuous process improvement, and rigorous adherence to military-grade quality standards. The Senior Manufacturing Engineer will ensure efficient process transitions, maintain product integrity, reduce production costs, and uphold strict compliance with defense manufacturing protocols.

Essential Duties and Responsibilities:

• Serve as the primary manufacturing representative on cross-functional engineering teams to lead and coordinate the smooth transition of new defense battery products from design to production.
• Design, organize, and continuously improve battery assembly areas to meet evolving product specifications, Department of Defense (DoD) requirements, and production throughput goals.
• Lead initiatives to streamline and optimize manufacturing workflows, enhancing product quality, reducing cycle time, minimizing scrap, and maximizing output.
• Define requirements for specialized production equipment, tooling, fixtures, and test setups specific to high-reliability, mission-critical battery manufacturing.
• Drive compliance with defense quality standards (e.g., MIL-STD, AS9100, IPC) across all manufacturing processes and work instructions.
• Develop and deliver technical training to production teams to ensure full compliance with documented procedures, quality standards, and engineering requirements.
• Manage manufacturing engineering and act as a subject matter expert for battery-specific manufacturing processes, materials, and technologies.
• Support audits, customer inspections, and quality assurance activities as needed to maintain defense manufacturing certifications.
• Determine the requirements for equipment, tools, fixtures and fulfill real-time production needs for our manufacture operations.
• Monitor rework and repair operations, consistently monitor and report yield issues, and regularly highlight significant findings.
• Conduct failure analysis, identify root causes, and pursue effective solutions to minimize in-process defects.

Qualifications:

• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Electrical Engineering, or a related technical field.
• 10+ years of experience in manufacturing engineering, with 3+ years specifically in battery production, defense manufacturing, or other mission-critical industries strongly preferred.
• Strong knowledge of battery technologies, including cell assembly, electrode processing, electrolyte handling, welding, sealing, environmental testing, chargers and accessories.
• In-depth experience with root cause analysis methodologies (e.g., 5 Whys, Fishbone Diagram, FMEA) and corrective action implementation (CAPA).
• Hands-on experience with designing and optimizing manufacturing processes, production lines, tooling, and fixtures.
• Familiarity with defense manufacturing standards and compliance requirements (e.g., MIL-STD, AS9100, ITAR).
• Proficient in statistical process control (SPC), lean manufacturing, Six Sigma tools, and continuous improvement principles.
• Ability to read and interpret engineering drawings, schematics, specifications, and work instructions.
• Strong technical writing skills to create clear work instructions, reports, and standard operating procedures (SOPs).
• Excellent communication skills, with the ability to work collaboratively in cross-functional teams.

General

Job Requirements:

Generic Ener Sys provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws.