Process Engineer – Lithium Battery Manufacturing

Employment Type: Full-Time

Location: Greater Greensboro, NC (actual location just in VA)

Industry: Advanced Manufacturing / Lithium Battery Materials

Travel: As Needed Between Manufacturing Facilities

Position Overview

We are seeking an experienced Process Engineer to support the development, optimization, and continuous improvement of manufacturing processes within a lithium battery separator production environment.

This position will be responsible for improving manufacturing performance across mixing, coating, slitting, material handling, and related production operations. The Process Engineer will utilize engineering principles, manufacturing data, and structured problem-solving methodologies to improve safety, product quality, yield, throughput, process stability, and operational efficiency.

The ideal candidate will have hands-on process engineering experience in lithium battery manufacturing, roll-to-roll processing, coating and converting, extrusion, plastics, chemical processing, or other advanced manufacturing environments. This individual will collaborate with Operations, Quality, Maintenance, Research & Development, EHS, and Supply Chain to resolve manufacturing challenges, implement process improvements, and support new product introductions and production scale-up.

Key Responsibilities

Manufacturing Process Engineering & Optimization

• Own and support assigned manufacturing processes, including mixing, coating, slitting, material handling, and separator production operations
• Analyze manufacturing performance and optimize process parameters to improve product quality, yield, throughput, and cost
• Establish and maintain operating parameters, process windows, setup standards, and engineering procedures
• Evaluate process capability and identify opportunities to improve manufacturing consistency and stability
• Support production startup, process validation, and equipment qualification readiness
• Identify and recommend improvements to manufacturing processes, equipment, controls, and material-handling systems
• Monitor manufacturing performance to ensure processes meet established safety, quality, and production requirements
• Develop practical engineering solutions that improve process reliability and operational efficiency
  
  
  

Continuous Improvement & Root-Cause Analysis

• Lead and support continuous improvement initiatives focused on scrap reduction, yield improvement, cycle-time reduction, and equipment reliability
• Troubleshoot complex manufacturing and process-related production issues
• Conduct structured Root Cause Analysis (RCA) and implement sustainable corrective actions
• Utilize Statistical Process Control (SPC), Design of Experiments (DOE), Process Failure Mode and Effects Analysis (PFMEA), and Lean/Six Sigma methodologies
• Analyze process trends, manufacturing losses, and equipment performance to identify improvement opportunities
• Develop and implement corrective actions to improve process capability and reduce production variability
• Evaluate recurring manufacturing defects and develop strategies to prevent future occurrences
• Support initiatives designed to improve production efficiency, process stability, and manufacturing performance
  
  
  

Process Development & Manufacturing Scale-Up

• Collaborate with Research & Development, Quality, and Operations teams to support new product introductions
• Support the development and scale-up of new manufacturing processes and materials
• Plan and execute pilot trials, production trials, and process validation activities
• Establish trial objectives, data collection requirements, performance criteria, and technical conclusions
• Evaluate new materials, technologies, manufacturing equipment, and processing methods
• Analyze trial results and recommend process adjustments to improve production readiness
• Translate product development findings into documented manufacturing standards and repeatable production processes
• Support the transition of new products and processes into full-scale manufacturing
  
  
  

Manufacturing Data Analysis & Process Control

• Collect and analyze manufacturing data, process parameters, quality results, and equipment performance metrics
• Utilize statistical and engineering analysis methods to evaluate process capability and stability
• Identify trends and recurring manufacturing losses that impact production performance
• Develop data-driven recommendations to improve manufacturing processes and operating conditions
• Support the development and maintenance of process monitoring and control methodologies
• Utilize manufacturing data analysis tools and historian systems to evaluate production performance
• Prepare technical reports, process documentation, and improvement recommendations
• Communicate process performance and improvement opportunities to engineering and operational leadership
  
  
  

Cross-Functional Engineering & Production Support

• Collaborate with Operations, Quality, Maintenance, R&D, EHS, and Supply Chain to resolve manufacturing challenges
• Provide technical support to production teams during process troubleshooting and equipment-related issues
• Partner with Maintenance and Engineering to improve equipment reliability and manufacturing performance
• Support quality improvement initiatives and manufacturing defect investigations
• Assist with implementation of process modifications and production improvements
• Maintain accurate engineering documentation, operating standards, and technical procedures
• Ensure process improvement activities support safety, quality, and operational objectives
• Manage multiple engineering projects and improvement initiatives within a fast-paced manufacturing environment
  
  
  

Required Qualifications

• Bachelor's degree in Mechanical Engineering, Industrial Engineering, or Manufacturing Engineering
• Strong understanding of manufacturing processes, engineering principles, and structured problem-solving methodologies
• Knowledge of manufacturing process optimization, troubleshooting, and continuous improvement
• Working knowledge of SPC, DOE, PFMEA, Root Cause Analysis, process capability, and Lean/Six Sigma methodologies
• Ability to analyze manufacturing data, equipment parameters, process trends, and quality results
• Strong analytical and technical problem-solving capabilities
• Proficiency with Microsoft Office applications
• Ability to utilize manufacturing data analysis tools or process historian systems
• Ability to manage multiple projects and competing priorities
• Strong written and verbal communication skills
• Ability to collaborate effectively with technical, manufacturing, and operational teams
• Strong attention to detail and commitment to safety, quality, and operational excellence
• Willingness to travel between manufacturing facilities as needed
  
  
  

Preferred Qualifications

• 3–7 years of process engineering experience in a manufacturing environment
• Direct experience in lithium battery manufacturing or battery separator production
• Experience with roll-to-roll manufacturing, web handling, coating, converting, or slitting operations
• Experience in extrusion, plastics manufacturing, chemical processing, or advanced manufacturing
• Hands-on experience troubleshooting manufacturing processes and optimizing production parameters
• Experience conducting production trials, process validation, and manufacturing scale-up
• Demonstrated success improving yield, reducing scrap, and increasing manufacturing throughput
• Experience implementing Lean manufacturing and Six Sigma continuous improvement initiatives
• Experience utilizing SPC, DOE, PFMEA, and statistical process improvement techniques
• Knowledge of process capability analysis and manufacturing process control
• Experience evaluating manufacturing equipment, process controls, and material-handling systems
• Experience supporting new product introductions and production readiness activities
• Experience collaborating with R&D, Quality, Maintenance, and Operations teams
  
  
  

Candidate Must-Haves

• Bachelor's degree in Mechanical, Industrial, or Manufacturing Engineering
• Strong understanding of manufacturing process engineering and optimization
• Knowledge of structured problem-solving and continuous improvement methodologies
• Ability to troubleshoot manufacturing processes and identify root causes of production issues
• Working knowledge of SPC, DOE, PFMEA, Root Cause Analysis, and Lean/Six Sigma principles
• Ability to analyze manufacturing data, process trends, and equipment performance
• Strong technical problem-solving and analytical capabilities
• Experience or technical knowledge relevant to process improvement and manufacturing operations
• Ability to develop and maintain engineering procedures and process documentation
• Strong cross-functional communication and collaboration skills
• Ability to manage multiple projects within a manufacturing environment
• Willingness to travel between manufacturing facilities as needed