Battery Pack Assembly Operations Manager

Full Time

• -Lead daily battery pack assembly operations and execute production schedules to achieve safety, quality, delivery, cost, and productivity targets.
• -Own pack manufacturing processes including cell preparation and traceability, module/pack assembly, busbar and electrical connections, welding, torque-controlled assembly, BMS/harness integration, thermal components, insulation, sealing, enclosure assembly, labeling, and final assembly.
• -Lead new product introduction and industrialization from prototype and engineering builds through qualification, pilot production, ramp, and stable manufacturing; support DFMA, PFMEA, Control Plans, work instructions, routings, CTQs, and production-readiness reviews.
• -Develop pack assembly capacity, staffing, floor-space, equipment, tooling, automation, and capital plans to support customer demand and future business growth.
• -Define and improve assembly equipment, fixtures, jigs, welding systems, torque tools, dispensing systems, material handling, and error-proofing; support commissioning, qualification, validation, and production handover.
• -Ensure Pack Assembly compliance with AS9100D requirements, including controlled documentation, configuration/change control, product and material traceability, training records, nonconformance control, corrective actions, risk-based thinking, and audit readiness.
• -Drive manufacturing quality through process controls, First Pass Yield improvement, defect prevention, root cause analysis, CAPA, and effective resolution of internal and customer quality issues.
• -Enforce EHS requirements and safe practices for lithium-ion batteries, high-voltage systems, welding, chemicals/adhesives, ergonomics, and pack/material handling.
• -Build standardized work, Lean manufacturing, 5S, visual management, line balancing, poka-yoke, and continuous-improvement practices to improve cycle time, labor productivity, yield, and cost.
• -Build, train, and develop Pack Assembly leads, technicians, and operators; establish skill matrices, certification requirements, cross-training, and clear performance accountability.
• -Maintain robust manufacturing traceability and support ERP/MES data collection for cells, modules, packs, critical components, process parameters, torque/weld records, material lots, and serial numbers.
• -Develop, track and report key KPIs including safety, OTD, schedule attainment, FPY/yield, scrap/rework, labor productivity, cycle time, throughput, OEE where applicable, downtime, capacity utilization, and manufacturing cost; develop recovery plans for performance gaps.
• -Communicate production status, customer commitments, risks, constraints, and mitigation plans to the VP Operations and cross-functional leadership.
• -Perform other duties as assigned.

• -Bachelor’s degree in Mechanical, Electrical, Manufacturing, or Industrial Engineering, Operations Management, or a related technical field; an equivalent combination of education and directly relevant battery manufacturing experience may be considered.
• -8+ years of manufacturing experience with 5+ years of direct battery module and/or battery pack manufacturing leadership experience.
• -Demonstrated experience leading pack assembly, NPI/industrialization, production ramp, capacity planning, and manufacturing teams.
• -Strong hands-on knowledge of lithium-ion pack architecture, assembly equipment/tooling, welding, electrical connections, torque-controlled assembly, BMS integration, thermal management, and enclosure assembly.
• -Working knowledge of AS9100 requirements and experience with controlled documentation, traceability, nonconformance/CAPA, audits, and structured quality systems.
• -Strong Lean manufacturing,…