What are the responsibilities and job description for the Process Engineer position at HSBMA LLC?
Process Engineer
Summary:
Battery manufacturing is composed of electrode, assembly and formation processes. In the Electrode process, raw materials are mixed and coated on to 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 work that includes but not limited to monitoring, analyzing, and reporting of production results, and ensuring high yield and productivity for each electrode, cell assembly and formation process by implementing and improving manufacturing methods and processes. This position will also need to interact with other teams and vendors to solve complex and/or urgent problems by identifying and evaluating alternatives or by providing needed information and advice. As working on a 24/7 facility, this position may require on-call support in various circumstances. Candidates should be motivated problem solvers that can provide creative solution approaches to your task with concern about effectiveness and quality that are well based in the technology expertise and best practices.
Electrode
- 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: To press the coated electrode materials. Pressing removes excess solvents and improves the density, adhesion
- Slitting: The machine uses sharp blades or rotary cutters to slice the sheet into narrower strips or ribbons of the desired width
Assembly
- Notching: Refers to the process where reel of electrode is cut into individual sheets with designed dimensions
- Vacuum Drying: 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: Tab welding connects a set electrode foils to tab.
- Packaging: The purpose of packaging is to place Jelly roll into formed pouch, fill with electrolyte and seal
Formation
- Pre-Charging: It is the initial charging process performed on a newly assembled battery pack.
- Degassing: It is a critical step that helps remove any excess or volatile gasses that may have accumulated within the battery cells.
- Aging: A controlled procedure where the battery cells are subjected to specific conditions to simulate their performance over time.
- Inspection: In inspection the battery cells undergo final testing to ensure they meet the required performance and quality standards.
Key Areas of Responsibility:
- 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 efficiency (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 effectively.
- Perform other duties as assigned.
Required Qualifications:
- Education: Bachelor’s degree or higher in Mechanical Engineering, Electrical Engineering, Chemical Engineering, or a related field
- Experiences: 3 years in high-volume manufacturing, preferably within the battery or related industry
Preferred Qualifications:
- Battery manufacturing experience
- Manufacturing experience related to the process of batteries (mixing, coating, slitting, notching, stacking, welding, packaging, and degassing)
Skills:
- Knowledge of battery production processes and equipment
- Proficiency in data analysis and statistical methods
- Familiarity with IT systems related to manufacturing, including MES and data verification tools
- Problem-solving and troubleshooting skills
- Effective communication and teamwork abilities
- Strong attention to detail and commitment to quality
Physical Requirements:
- The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job.
- Ability to safely and successfully perform the essential job functions consistent with the ADA, FMLA and other federal, state and local standards.
- Ability to maintain regular, punctual attendance consistent with the ADA, FMLA and other federal, state and local standards.
- May occasionally left and/or move up to up to 50 pounds.
- Must be able to regularly stand, walk, sit, talk or hear. The employee is occasionally required to reach with hands and arms to include stoop, kneel, bend or crawl.
Physical & Mental Demands
- Office Environment: Must wear company-provided uniforms.
- Production Site: Must wear company-provided uniform and PPE including safety shoes, helmet, safety glasses, and portable gas measuring device.
Work Environment
- Usual office environment, production, and construction sites
- Risks include noise (above 90 dB in compressor room), high temperatures (104–122°F in various rooms), and potential exposure to hazardous materials (e.g., heating medium oil, NMP, water treatment chemicals)