Battery Pack Assembly Operations Manager

Company Description American Lithium Energy (ALE) is a leading clean energy company specializing in advanced lithium-ion battery technology for electric vehicles, renewable energy systems, and grid storage solutions. ALE’s batteries deliver superior performance, high energy density, and long service life, supporting efficient energy storage and reliable renewable power integration. The company is committed to sustainability through responsible sourcing and manufacturing practices that minimize environmental impact and uphold high industry standards. ALE’s success is driven by a team of experienced professionals and a strong focus on innovation, collaborating with industry partners, research institutions, and customers to develop breakthrough energy storage technologies. Joining ALE means contributing to a cleaner, more sustainable future while working at the forefront of the clean energy market.

Role Description

The Battery Pack Assembly Operations Manager is responsible for leading and scaling ALE’s battery pack assembly operations, with ownership of safety, quality, delivery, cost, productivity, people, equipment, and manufacturing readiness. The role leads pack programs from prototype/NPI through production ramp and stable manufacturing, while developing the people, processes, tooling, capacity, and operating systems required to support ALE’s growing pack assembly business. The Manager works closely with customers, R&D, Engineering, Quality, Supply Chain, EHS, and Operations and ensures Pack Assembly activities comply with Company’s AS9100D Quality Management System and applicable customer requirements.

Duties and Responsibilities

• Lead daily battery pack assembly operations and execute production schedules to achieve safety, quality, delivery, cost, and productivity targets.
• Own pack manufacturing processes including cell preparation and traceability, module/pack assembly, busbar and electrical connections, welding, torque-controlled assembly, BMS/harness integration, thermal components, insulation, sealing, enclosure assembly, labeling, and final assembly.
• Lead new product introduction and industrialization from prototype and engineering builds through qualification, pilot production, ramp, and stable manufacturing; support DFMA, PFMEA, Control Plans, work instructions, routings, CTQs, and production-readiness reviews.
• Develop pack assembly capacity, staffing, floor-space, equipment, tooling, automation, and capital plans to support customer demand and future business growth.
• Define and improve assembly equipment, fixtures, jigs, welding systems, torque tools, dispensing systems, material handling, and error-proofing; support commissioning, qualification, validation, and production handover.
• Ensure Pack Assembly compliance with AS9100D requirements, including controlled documentation, configuration/change control, product and material traceability, training records, nonconformance control, corrective actions, risk-based thinking, and audit readiness.
• Drive manufacturing quality through process controls, First Pass Yield improvement, defect prevention, root cause analysis, CAPA, and effective resolution of internal and customer quality issues.
• Enforce EHS requirements and safe practices for lithium-ion batteries, high-voltage systems, welding, chemicals/adhesives, ergonomics, and pack/material handling.
• Build standardized work, Lean manufacturing, 5S, visual management, line balancing, poka-yoke, and continuous-improvement practices to improve cycle time, labor productivity, yield, and cost.
• Build, train, and develop Pack Assembly leads, technicians, and operators; establish skill matrices, certification requirements, cross-training, and clear performance accountability.
• Maintain robust manufacturing traceability and support ERP/MES data collection for cells, modules, packs, critical components, process parameters, torque/weld records, material lots, and serial numbers.
• Develop, track and report key KPIs including safety, OTD, schedule attainment, FPY/yield, scrap/rework, labor productivity, cycle time, throughput, OEE where applicable, downtime, capacity utilization, and manufacturing cost; develop recovery plans for performance gaps.
• Communicate production status, customer commitments, risks, constraints, and mitigation plans to the VP Operations and cross-functional leadership.
• Perform other duties as assigned.

Qualifications

• Bachelor’s degree in Mechanical, Electrical, Manufacturing, or Industrial Engineering, Operations Management, or a related technical field; an equivalent combination of education and directly relevant battery manufacturing experience may be considered.
• 8+ years of manufacturing experience with 5+ years of direct battery module and/or battery pack manufacturing leadership experience.
• Demonstrated experience leading pack assembly, NPI/industrialization, production ramp, capacity planning, and manufacturing teams.
• Strong hands-on knowledge of lithium-ion pack architecture, assembly equipment/tooling, welding, electrical connections, torque-controlled assembly, BMS integration, thermal management, and enclosure assembly.
• Working knowledge of AS9100 requirements and experience with controlled documentation, traceability, nonconformance/CAPA, audits, and structured quality systems.
• Strong Lean manufacturing, problem-solving, and continuous-improvement capability; experience with PFMEA, Control Plans, 5-Why, 8D, and root cause analysis.
• Strong leadership, employee-development, communication, conflict-resolution, prioritization, and decision-making skills, with the ability to work effectively across technical and operational functions.
• Hands-on, resourceful, accountable, and comfortable working directly on the manufacturing floor in a fast-growing environment.

Direct Reports

• Pack Assembly Leads, Technicians, and Operators

Export-control Requirements

This position may require access to export-controlled technical data, hardware, or systems. Candidates must qualify as a U.S. person under applicable export-control laws or otherwise be eligible to obtain any authorization required for the position.

Work Environment/Physical Requirements

Work is performed in an advanced lithium-ion battery manufacturing environment requiring PPE and strict safety practices. Regular presence on the manufacturing floor is required. The employee must be able to stand and walk for extended periods; bend, squat, reach, and use hands and arms to support manufacturing activities; and safely lift, push, or pull up to 50 pounds, with or without reasonable accommodation.

Equal Employment Opportunity

American Lithium Energy Corporation is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, protected veteran status, or any other characteristic protected by applicable federal, state, or local law.

Salary: $80k - $130k

Job Type: Full-Time, exempt role and onsite.