Sr. Process Engineer

About AESC US LLC AESC is a global leader in the development and manufacturing of high-performance batteries for zero-emission electric vehicles and energy storage systems. Founded in Japan in 2007 and headquartered in Yokohama, AESC has been building manufacturing capabilities around the world in the U.S., U.K., Europe, Japan and China to serve key markets and leading customers locally for over 14 years. Today, AESC has become the partner of choice for the world’s leading OEMs and energy storage providers in North America, Europe, and Asia. Its advanced technology powers over one million electric vehicles and provides more than 15GWh of installed capacity for battery energy systems in over 60 countries. Exceptional Growth in the United States AESC is expanding its footprint in the United States with gigafactories in Kentucky, South Carolina, and Tennessee to meet the growing demand for EV and BESS batteries and strengthen its presence in the North American market. AESC's Tennessee gigafactory in Smyrna, which has been operational and supplying electric vehicle batteries for the Nissan LEAF since 2012, was retooled in 2025 and now produces batteries for Energy Storage Systems. The South Carolina gigafactory in Florence will supply next generation cells for BMW starting in 2026. The Kentucky gigafactory in Bowling Green will supply high-performance batteries and components for other OEMs. AESC is committed to our local communities where it is making its investments, creating jobs, and supporting local charities. About the Role The Senior Process Engineer is the technical lead for AESC’s repack operation, responsible for designing, stabilizing, and continuously improving the processes that support battery module inspection, rework, repackaging, and outbound fulfillment. This role sits at the intersection of engineering rigor and production reality — where process discipline, material flow, traceability, and cycle time efficiency are directly tied to customer commitments and site profitability. Beyond the technical scope, this position is structured for an engineer with the ambition and capability to grow into engineering management. The Senior Process Engineer will mentor junior engineers and technicians, lead cross‑functional initiatives, and build the leadership presence and operational judgment that form the foundation for formal management responsibilities as the operation scales. What You Will Do Process Ownership & Optimization: Own the end‑to‑end process for assigned repack work cells, including disassembly, inspection, rework, repackaging, labeling, and kitting; define and maintain control parameters, monitor throughput and quality KPIs, and drive sustained improvements in cycle time, first‑pass yield, and material utilization. Technical Troubleshooting & Problem Solving: Lead root cause investigations for process escapes, rework defects, material handling failures, and quality deviations using structured methodologies (8D, RCA, FMEA); develop corrective and preventive actions and track effectiveness through sustained performance metrics. Equipment, Tooling & Fixture Management: Lead engineering scope for repack‑specific capital investments, including material handling equipment, inspection fixtures, test stations, and packaging machinery; manage vendor qualification, FAT/SAT sign‑off, and production readiness from procurement through steady‑state operation. Engineering Standards & Documentation: Develop and maintain process control plans, work instructions, PFMEAs, and visual standards for repack work cells; ensure documentation is current, accurate, and written at a level that supports operator training and audit readiness under IATF 16949 and customer‑specific requirements. Continuous Improvement Leadership: Identify and lead Kaizen events, line balancing exercises, and waste reduction initiatives focused on repack‑specific losses — including excessive rework loops, material handling inefficiencies, and packaging variation; mentor junior engineers and technicians through improvement projects while building sustainable team capability. New Program Introductions & Process Transfers: Lead process engineering activities for new repack SKUs, customer program launches, and inbound product transitions; develop work cell layouts, time studies, and operator qualification plans that enable rapid, repeatable ramp‑up with minimal quality risk. Safety & Regulatory Compliance: Champion a culture of safety within the engineering team and on the plant floor; conduct process and safety audits, ensure engineering changes comply with applicable standards (IATF 16949, ISO 14001, OSHA), and actively participate in risk assessments for new processes and equipment. Cross‑Functional & Team Leadership: Act as the engineering lead on cross‑functional project teams, providing direction to contractors, technicians, and junior engineers; model collaborative problem‑solving, set clear priorities, and develop the technical and professional skills of those around you as a precursor to formal people management responsibilities. Data Analysis & Process Control: Use SPC, time studies, and line efficiency data to monitor repack process stability, identify variation sources, and validate improvement actions; build reporting that gives operations leadership clear, actionable visibility into cost‑per‑unit, rework rates, and throughput trends. Stakeholder Communication & Reporting: Prepare and present engineering updates, project status, and improvement results to plant leadership and senior management; communicate technical findings in a clear, structured manner that supports decision‑making and builds confidence in the engineering team’s execution. Complete other duties as assigned. What You Need Education: Bachelor’s degree in Industrial, Electrical, Mechanical, or Chemical Engineering. Experience: 7+ years of process engineering experience in a high‑volume manufacturing or distribution/fulfillment environment, with direct ownership of production processes, quality systems, and continuous improvement initiatives; experience in repack, kitting, rework, or value‑added operations is strongly preferred. Skills: Demonstrated mastery of structured problem‑solving methodologies (8D, RCA, FMEA, DOE) with a track record of resolving chronic process issues and sustaining results; ability to coach others through these frameworks. Proficient in Microsoft Office applications, AutoCAD, and Inventor. Proven ability to manage multiple concurrent engineering projects from initiation through close, including capital equipment commissioning, new product introduction, and process improvement initiatives; comfortable setting priorities and holding timelines in a fast‑paced environment. Familiarity with battery module or pack handling, storage requirements, and safety protocols is an advantage; candidates from adjacent industries involving high‑mix, low‑volume, or inspection‑intensive operations are also well‑positioned for this role. Self‑directed and highly organized, with the ability to manage competing priorities independently while keeping cross‑functional stakeholders informed; demonstrated willingness to take ownership and drive closure without waiting for direction. Experience managing contractors, suppliers, and external engineering resources through the full project lifecycle, from RFP and vendor selection through commissioning and production start‑up. Strong communicator with the confidence to present technical findings and recommendations to senior leadership; able to adapt style for operators, engineers, and executives alike, and to influence decisions without direct authority. Proficient in Microsoft Office (Excel, PowerPoint), AutoCAD, and data reporting tools; experience building dashboards or structured reporting that plant leadership can act on. Experience standing up or significantly restructuring a repack, rework, or value‑added operation, including developing work cell layouts, labor standards, and process documentation from early stages; comfort building structure in environments where processes are still being defined. Demonstrated ability to lead through influence in cross‑functional settings and an expressed interest in growing into engineering management; candidates who have informally mentored peers, led project teams, or taken on coordination responsibilities are encouraged to highlight that experience. Understands and follows all standards of IATF 16949 and VDA 6.3 quality standards. Training and awareness will be provided for those who are not familiar with these standards. Understands and follows all standards of ISO 14001 environmental standards. Training and awareness will be provided for those who are not familiar with these standards. Nice to Have People Leadership Trajectory: Prior experience formally or informally leading other engineers, technicians, or project teams; a clear interest in growing into an engineering management role and the self‑awareness to articulate what that path looks like for you. Greenfield/Brownfield Start‑Up Experience: Hands‑on involvement in new plant construction, retooling, or capacity expansion, with a working understanding of how to build and stabilize processes in environments where systems and standards are still maturing. Project Management Certification: PMP or equivalent; or demonstrated application of formal project management methodology on capital or NPI programs. Lean Six Sigma Certification: Green Belt or Black Belt, with applied project experience; candidates who have led Kaizen events or VSM initiatives in a production environment are particularly well‑positioned. Battery or EV Supply Chain Background: Exposure to lithium‑ion battery handling, warehouse management systems (WMS), serialization/traceability requirements, or OEM‑driven packaging standards within an automotive or energy storage supply chain. Advanced Quality Tools: Working proficiency in PFMEA, Control Plans, MSA, and DOE; experience applying these tools in a production launch or process validation context rather than purely in a design or quality assurance role. Bilingual Proficiency: Japanese, Mandarin, or Spanish language skills are a plus given the global nature of AESC’s operations and supplier base. Travel Occasional domestic and international travel required. What We Offer Welcome to AESC, where you'll have the opportunity to tackle the world's most fascinating challenges alongside exceptionally talented individuals who are driven to make a difference. We strive to ensure that our employees are well taken care of, enabling them to focus on their work and contribute to our collective mission. We offer: Comprehensive compensation packages including a competitive salary and a rewarding bonus program. An inclusive and diverse work environment that fosters and encourages professional and personal development. Highly automated, clean, safe, and temperature‑controlled production environment. Medical, Dental and Vision Insurance. HSA and Flexible Spending Accounts. 401K with company match. Life Insurance (Company paid and additional voluntary life available). Paid Vacation and 14 Paid Holidays. Short term and long‑term disability coverage (Company Paid). Application Process Even if you don't meet every requirement, we encourage you to apply. Your application allows us to learn more about you and find potential fits within our team. We strive to respond to all applicants promptly, though times may vary with submission volume. If you don't receive an immediate response, it doesn't reflect on your candidacy; we'll keep your application for future opportunities. Thank you for your patience and enthusiasm as we improve our application process. At AESC, we are committed to providing Equal Employment Opportunity (EEO) to all individuals. We participate in E‑Verify and will provide the federal government with your Form I‑9 information to confirm that you are authorized to work in the U.S. Join us in our passion to design, manufacture, and sell high‑performance products, contributing to a sustainable and zero‑carbon emission future. 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. Reasonable accommodation may be made to enable otherwise qualified individuals with disabilities to perform the essential job functions. Ability to sit for extended periods of time. Ability to read, write, speak, hear, stand, walk, use hands to finger, handle, or feel, reach and lift with hands and arms frequently throughout the day. Required to occasionally lift, push, pull and/or move up to 10 pounds and occasionally required to lift, push, pull and/or move up to 35 pounds. The work environment is primarily an automated manufacturing plant with a concrete floor and is characterized by some temperature extremes, moderate noise, and forklift traffic. The individual must be able to perform all essential functions as appropriate on the plant floor, in meetings, and with employees, management, customers and suppliers. Candidate must perform the essential duties and responsibilities with or without reasonable accommodation efficiently and accurately, and without causing significant safety threat to self or others. The statements made herein are intended to describe the general nature and level of work being performed by employees assigned to this job classification. They are not intended to be construed as an exhaustive and inclusive list of all responsibilities, duties, or skills required of personnel so classified. Hiring is contingent upon successful completion of drug screen and background check. AESC US LLC is a drug‑free workplace. #J-18808-Ljbffr