Sr. Engineer, New Product Introduction (NPI)
About The Position
LG Energy Solution Arizona, Inc. is seeking a site-level NPI execution lead for battery cell development and mass production transfer projects led by Headquarters NPI/R&D in South Korea. The role manages end-to-end on-site execution, from pilot line validation through mass production stabilization, in alignment with HQ guidelines. The NPI Engineer collects cell assembly process data, supports customer PPAP approval, stabilizes initial production yield, and optimizes process parameters. The position supports new cell line transfers and ramp-ups, validates assembly process parameters, prepares information for NPI gate reviews, and assists with PPAP data packages and customer audits. It also aligns site quality documentation with HQ standards, manages ramp-up yield and process capability, investigates defects, optimizes process parameters, transfers validated process knowledge to manufacturing and quality teams, and documents approvals for NPI-phase 4M changes.
Requirements
- Bachelor’s degree or higher in Engineering, such as Chemical, Materials, Mechanical, or Electrical Engineering, or a related field.
- At least 7 years of experience in NPI, Process Engineering, or Quality Engineering in manufacturing.
- Hands-on experience generating PPAP documentation and datasets, including PFMEA, Control Plan, MSA, and Cpk/Ppk.
- Problem-solving skills for shop-floor issues using methods such as 8D reports or 5-Why.
- Proficiency in statistical data analysis tools, including Minitab and SPC.
Nice To Haves
- Battery cell assembly experience.
- Professional working proficiency in English, written and verbal, for collaboration with HQ and global clients.
- Understanding of quality systems and methods such as Six Sigma, DOE, and statistical tools.
- Experience with HQ-to-plant technology transfer projects for new battery cell products.
- Experience with customer PPAP submissions and audit responses under IATF 16949 quality standards.
Responsibilities
- Execute pilot runs and DV/PD/PV (Design/Process Development/Production Validation) sample builds according to HQ R&D/NPI schedules.
- Validate assembly process recipes and parameter settings transferred from HQ, including welding conditions, electrolyte amount, and pressing force.
- Analyze data variance across equipment and lines, and provide engineering feedback to HQ R&D.
- Prepare and share line uptime, cell yield, and bottleneck analysis reports for NPI Gate Reviews.
- Collect and submit assembly process capability data (Cpk/Ppk), Gauge R&R, and MSA data requested by HQ Quality or Customer Support teams.
- Localize and update site-specific PFMEAs, Standard Operating Procedures (SOPs), and inspection standards based on HQ standard documents, including DFMEA/PFMEA and Control Plans.
- Lead line tours and demonstrate key assembly and inspection processes during customer audits; implement corrective actions for audit findings.
- Monitor ramp-up yield trends, conduct Pareto analysis of defect types, and control process variation to achieve target capability for key assembly processes.
- Issue 8D reports for NPI-stage defects, investigate root causes using cross-sectional analysis, and report findings to HQ.
- Optimize laser welding parameters, electrolyte injection and soaking time, and humidity and pressure controls to reduce defect rates.
- Transfer validated assembly process know-how, safety guidelines, and operating precautions to site manufacturing and quality teams.
- Document and manage approvals for 4M (Man, Machine, Material, Method) changes during the NPI phase.
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What This Job Offers
Job Type
Full-time
Career Level
Senior
