Sr. Process Engineer

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

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. 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 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.

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.

• 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.
• 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.
• 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.
• 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.
• 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.
• 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.
• 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…