Process Engineer - Jelly Roll Winding and Cell Assembly

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

The Specialist, Jelly Roll Winding & Cell Assembly - Battery Cells is responsible for the development, optimization, industrialization, and support of cylindrical lithium-ion battery cell winding and assembly processes. This role focuses on jelly roll winding, electrode and separator handling, tab connection, can insertion, and related assembly operations that directly impact cell quality, safety, reliability, and manufacturing performance.
The position works closely with Engineering, Manufacturing, Quality, Maintenance, Automation, EHS, Product Development, and equipment suppliers to establish robust and scalable manufacturing processes from pilot operations through commercial production. The successful candidate combines strong technical expertise with a hands-on approach to manufacturing excellence and continuous improvement.

Essential Duties and Responsibilities

• Develop, optimize, and sustain jelly roll winding processes for cylindrical lithium-ion battery cell formats including 18650, 21700, and 46xx cells.
• Define, validate, and control critical winding parameters including web tension, winding speed, alignment, overlap, separator handling, mandrel design, and jelly roll geometry.
• Support cell assembly operations including electrode preparation, tab welding, insulation application, jelly roll insertion, beading, sealing, electrolyte filling interfaces, and pre-formation preparation activities.
• Analyze process performance and implement improvements to increase yield, throughput, process capability, operational efficiency, and product quality.
• Investigate and resolve manufacturing defects including alignment issues, separator damage, winding defects, dimensional deviations, contamination concerns, burr-related defects, and internal short risks.
• Support equipment selection, supplier technical reviews, Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), commissioning, qualification, and production startup activities.
• Collaborate with process engineering, product development, quality, maintenance, automation, and production teams to transfer processes from development and pilot operations to high-volume manufacturing.
• Develop and maintain process documentation including work instructions, process standards, training materials, PFMEA inputs, control plans, and operating procedures.
• Apply structured problem-solving methodologies including Root Cause Analysis, 8D, SPC, process capability analysis, and continuous improvement techniques.
• Ensure compliance with dry-room standards, safety requirements, quality systems, contamination control requirements, and battery manufacturing best practices.
• Participate in startup, commissioning, technology transfer, and manufacturing readiness activities supporting Gigafactory deployment and production ram

Qualifications

• Bachelor's degree in Mechanical Engineering, Production Engineering, Electrical Engineering, Manufacturing Engineering, Battery Technology, or a related technical discipline required. Technician or master craftsman qualifications with significant applicable experience may also be considered.
• Three (3) or more years of experience in lithium-ion battery manufacturing with emphasis on cylindrical cell winding and assembly operations preferred.
• Experience supporting equipment qualification, process validation, commissioning, startup, and production ramp-up activities preferred.
• Experience working in high-volume automated manufacturing environments preferred.
• Proficiency with Microsoft Office applications.
• Experience with MES, SCADA, manufacturing databases, automated inspection systems, and production reporting tools preferred.
• Experience with process monitoring and data analysis tools preferred.
• Six Sigma Green Belt or Black Belt certification preferred.
• Additional manufacturing, quality, or engineering certifications are beneficial.
• Domestic and international travel is required.

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.