Process Engineer

Summary

Battery manufacturing is composed of electrode, assembly and formation processes. In the Electrode process, raw materials are mixed and coated onto foils to make electrode sheets. Then, electrode components are stacked, welded and packaged in a cell housing during the Assembly process. Finally, through the Formation process the assembled cell is activated with electric energy and tested to evaluate its performance and characteristics.

Battery process engineer is responsible for monitoring, analyzing, and reporting production results, and ensuring high yield and productivity for each electrode, cell assembly, and formation process by implementing and improving manufacturing methods and processes. The position also interacts with other teams and vendors to solve complex and urgent problems, identifying and evaluating alternatives or providing needed information and advice. As the facility operates 24/7, the role may require on‑call support in various circumstances.

Candidates should be motivated problem solvers who can provide creative solution approaches to tasks with concern about effectiveness and quality, grounded in technology expertise and best practices.

• Mixing:
  The active materials are mixed by combining the processed metal oxides with a conductive additive and a binder.
• Coating:
  This mixture is called a slurry, which is then coated onto metal foil sheets, typically aluminum or copper.
• Pressing:
  The coated electrode materials are pressed to remove excess solvents and improve density and adhesion.
• Slitting:
  The machine uses sharp blades or rotary cutters to slice the sheet into narrower strips or ribbons of the desired width.

• Notching:
  Refers to the process where a reel of electrode is cut into individual sheets with designed dimensions.
• Vacuum Drying:
  Removes moisture from sheets of electrodes to ensure low moisture content in assembled battery cells.
• Stacking:
  The cathode and anode foils are stacked together with a separator material in between to create a jelly roll‑like structure.
• Tab welding:
  Connects a set of electrode foils to a tab.
• Packaging:
  Places the jelly roll into a formed pouch, fills with electrolyte and seals.

• Pre‑Charging:
  The initial charging process performed on a newly assembled battery pack.
• Degassing:
  Removes any excess or volatile gases that may have accumulated within the battery cells.
• Aging:
  Controlled procedure where the battery cells are subjected to over time.
• Inspection:
  Final testing to ensure the battery cells meet required performance and quality standards.

• Troubleshooting and solutions:
  Identify and resolve issues in processes, product quality, and equipment by developing effective solutions.
• Data analysis:
  Examine production raw data to conduct defect analysis, determine root causes, and implement corrective actions.
• Performance improvement:
  Monitor and enhance yield, overall equipment effectiveness (OEE), and parts per million (PPM) in electrode, assembly, and formation production processes.
• Compliance Monitoring:
  Oversee operating conditions at each production stage to ensure adherence to process regulations and address malfunctions.
• Technical Expertise:
  Provide technical support to ensure production aligns with quality, efficiency, and safety standards, including preparation for production runs, oversight during production, and managing changes in instructions or materials.
• PFMEA (Process Failure Mode and Effects Analysis) Management:
  Regularly review and update Process Failure Mode and Effects Analysis (PFMEA).
• Reporting:
  Communicate key production activities, results, and indicators on a daily or weekly basis.
• Team Collaborations:
  Work collaboratively with Engineers, Supervisors, and Operators to achieve production milestones.
• Training:
  Prepare and update work instructions, and provide training for new employees.
• Continuous Improvement:
  Enhance the production environment using 5S (Sort, Set in Order, Shine, Standardize, Sustain) and 3R (Right Material, Right Quantity, Right Position) standards.
• IT Systems:
  Utilize production‑related IT systems such as MES and other data verification tools…