Senior Staff Quality Engineer, Battery Manufacturing
Sila•Alameda, CA
•$156,000 - $197,000•Onsite
About The Position
In this highly visible role, you will have the opportunity to make a significant impact on next-generation battery products and establish quality systems that scale from development through high-volume production. You will serve as the critical bridge between our internal cell engineering and product teams and the factory floor—enabling the reliable, high-yield manufacture of advanced battery cells.
Requirements
- Minimum of 12 years of related experience with a Bachelor’s degree; or 8 years and a Master’s degree; or a PhD with 5 years experience; or equivalent experience.
- Hands-on experience in lithium-ion cell manufacturing processes and product qualification
- Familiarity with battery-specific metrology: coating weight, electrode thickness and density, porosity, tab alignment, and electrolyte fill weight measurement and control
- Strong command of quality and problem-solving tools: DOE, RCCA/8D, SPC, GR&R/MSA, PFMEA, control plans, and capability analysis (Cpk/Ppk)
- Knowledge of reliability methods relevant to batteries: Weibull analysis, HALT/HASS, accelerated life testing, and electrochemical failure mode characterization
- Familiarity with GD&T, tolerance stack-up analysis, and metrology best practices in a precision manufacturing context
- Experience managing CM/OEM quality relationships in Asia; ability to navigate cultural and organizational dynamics effectively
- Track record of developing manufacturing process documentation that captures process rationale, critical control points, failure modes and equipment constraints.
- Working knowledge of battery safety standards and certification pathways (IEC, UL, GB/T, KC, PSE)
- Strong cross-functional communication skills; comfortable presenting technical findings to engineering and executive audiences
Responsibilities
- Manage IQC, IPQC, OQC, and ORT across battery cell production lines
- Drive quality readiness at the Contract Manufacturer (CM) for development builds (EVT/DVT/PVT) and mass production ramp, including establishing inspection and hold/release protocols
- Lead root cause and corrective action (RCCA) investigations for quality escapes; present findings and closure plans to internal and CM leadership as required
- Collaborate with cell engineering and teams to define and implement appropriate quality control, inspection, and metrology stations across the full cell production process (electrode coating and calendering, winding/stacking, electrolyte filling, formation, aging, and final test)
- Define and monitor electrochemical quality metrics, identify process signals and drive SPC implementation
- Conduct periodic factory quality reviews covering yield, scrap, defect Pareto, and process capability trends
- Prepare OK-to-Ship and lot dispositioning documentation for new product launch and ongoing mass production
- Develop and maintain risk assessments (PFMEA) for battery manufacturing processes; implement control plans and reaction plans for identified risk items
- Support DFM reviews with cell design and product teams; conduct tolerance analysis for electrode stack, cell can/pouch dimensions, and assembly fit to ensure process capability against specification
- Develop and execute module and cell reliability test plans (cycle life, calendar aging, thermal abuse, mechanical) during NPI and MP, in coordination with internal engineering teams
- Ensure manufacturing process controls are sufficient to maintain compliance with applicable safety and certification standards (IEC 62133, UN 38.3, UL 1642, GB/T equivalents as applicable) at the production level
- 30–40% international travel to CM sites in Asia required
Benefits
- Base pay is only one part of Sila’s competitive Total Rewards package that can include benefits, perks, equity, and bonuses.
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What This Job Offers
Job Type
Full-time
Career Level
Senior
