Principal Quality Engineer I

EnerSys is a 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

We are seeking an experienced and technically strong Principal Quality Engineer to support the launch of our new lithium‑ion cell manufacturing facility. This role will play a key part in establishing initial manufacturing quality processes, defining APQP elements and control plans, and creating early documentation and controls that will enable a successful facility start-up. The ideal candidate has a strong background in high-volume high‑reliability manufacturing and experience contributing to quality system elements in early-stage environments in highly regulated environments. This is a unique opportunity to influence the foundation of a new production site and help ensure that manufacturing quality processes, controls, and procedures are implemented effectively and sustainably.

Essential Duties and Responsibilities

• Develop, implement, and mature manufacturing quality processes, inspection methods and standards, sampling strategies, acceptance criteria, and control documentation for lithium‑ion cell production.
• Development and execution of APQP deliverables, including PFMEA, Process Flow Diagrams, Control Plans, MSA, and PPAP documentation.
• Develop and deliver training programs for future employees on APQP fundamentals, quality tools, defect prevention, and process controls.
• Lead and coordinate APQP and manufacturing quality activities across Manufacturing, Engineering, R&D, and Supply Chain for new product introductions and new process deployments and act as liaison with customer representatives as required.
• Lead or support equipment and process qualification/validation activities including IQ/OQ/PQ development, data evaluation, and risk reviews.
• Collaborate across departments to implement and sustain robust process controls and manufacturing quality standards.
• Provide manufacturing quality input to Engineering DFMEA activities to ensure product design risks are aligned with process capabilities and quality controls.
• Establish baseline quality metrics and process controls during equipment commissioning, pilot builds, and production ramp‑up.\
• Perform statistical analysis, process capability assessments, and SPC implementation for critical manufacturing processes and identify improvement opportunities.
• Conduct manufacturing process audits to ensure compliance with documented processes and control plans.
• Provide technical guidance and training to engineers and technicians during facility launch, initial production runs, and quality system implementation.

Qualifications

• Bachelor’s degree in engineering (Mechanical, Electrical, Chemical, Materials, Manufacturing, Industrial, or related field). Master’s or PhD preferred.
• 10+ years of quality engineering experience in high‑volume highly regulated manufacturing environment, with a minimum of 8+ years in lithium-related manufacturing.
• Experience launching new manufacturing lines or processes, with direct involvement in developing manufacturing quality controls and documentation.
• Proficiency with statistical analysis tools (Minitab, JMP, Python, etc.).
• Proficiency in Microsoft Office Suite (Word, Excel, PowerPoint).
• Experience with ERP, PLM, MES systems (SAP, Oracle, PTC Windchill, etc.) is a plus

Preferred Qualifications
•Direct experience in cylindrical lithium‑ion cell manufacturing processes (mixing, coating, calendering, slitting, winding, welding, filling, formation, etc.).
•Background in electrochemistry or battery quality engineering.
•Lean Six Sigma Black Belt or higher.
•ASQ Certified Quality Engineer or equivalent.
•Certified ISO 9001, IATF 16949, or VDA 6.3 auditor preferred.

EnerSys provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws.

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