Principal Manufacturing Engineer

EnerSys is the global leader in stored energy solutions for industrial applications. We have over thirty manufacturing and assembly plants worldwide servicing over 10,000 customers in more than 100 countries. Worldwide headquarters are located in Reading, PA, USA with regional headquarters in Europe and Asia. We complement our extensive line of Motive Power and Energy Systems with a full range of integrated services and systems. With sales and service locations throughout the world, and over 100 years of battery experience, EnerSys is the power/full solution for stored DC power products. 

 

Job Purpose

The Principal Manufacturing Engineer will serve as the technical and managerial lead for manufacturing processes at the Lithium Gigafactory, combining expert technical knowledge with strong leadership capabilities. This role is responsible for overseeing the design, optimization, and scaling of manufacturing processes for lithium-ion cells, while also managing a team of engineers and cross-functional collaborators. You will drive innovation, ensure production excellence, and lead strategic projects that align with company objectives. In addition to technical oversight, you will be responsible for mentoring and developing team members, managing resources, and ensuring the smooth operation of day-to-day manufacturing activities.

Essential Duties and Responsibilities

Strategic Leadership in Manufacturing:

• Lead the development and implementation of advanced manufacturing processes for lithium-ion cells, focusing on improving energy density, safety, cost efficiency, and scalability.
• Set long-term strategies for process optimization, ensuring alignment with company goals for product performance, cost, and operational efficiency.
• Oversee the introduction of new technologies, materials, and manufacturing techniques, leveraging data-driven insights and simulation tools.

Managerial and Supervisory Responsibilities:

• Manage a team of engineers, including recruitment, training, performance evaluations, and career development.
• Provide day-to-day leadership and support for engineering staff, assigning tasks, monitoring progress, and ensuring project deadlines and milestones are met.
• Foster a collaborative and inclusive team culture focused on innovation, continuous improvement, and professional growth.
• Ensure clear communication and alignment of goals across the team, offering mentorship and technical guidance as needed.

Project and Program Management:

• Lead large-scale, high-impact manufacturing projects, overseeing resource allocation, budgeting, and scheduling.
• Coordinate with cross-functional teams, including R&D, product development, and supply chain, to ensure timely and successful project completion.
• Serve as the primary point of contact for senior leadership on manufacturing initiatives, providing updates on project progress, KPIs, and strategic recommendations.

Process Innovation and Optimization:

• Spearhead initiatives to enhance manufacturing efficiency, reduce production costs, and improve the overall performance and reliability of lithium-ion cells.
• Identify and implement cutting-edge automation solutions, advanced materials, and manufacturing processes.
• Oversee pilot-scale production and manage the transition of new processes to full-scale manufacturing operations.

Quality Assurance and Compliance:

• Ensure that all manufacturing processes adhere to industry regulations (e.g., UN/DOT, IEC, ISO) and internal quality standards.
• Work with quality assurance teams to address production or performance issues and implement corrective actions to maintain product excellence.
• Develop and monitor key performance indicators (KPIs) for production efficiency, product quality, and process reliability.

Collaboration and Cross-Functional Engagement:

• Partner with internal teams, including materials scientists, chemists, mechanical engineers, and supply chain managers, to ensure seamless integration of new designs and processes into production.
• Collaborate with external suppliers and partners to optimize materials and components for the lithium-ion manufacturing process.

Continuous Improvement and Sustainability:

• Lead continuous improvement initiatives focused on enhancing product quality, safety, and sustainability, while minimizing costs and environmental impact.
• Drive efforts to reduce waste, improve energy efficiency, and implement eco-friendly manufacturing practices within the plant.

Supervisory and Team Leadership:

• Act as a mentor to mid-level and senior engineers, developing their technical and lea