Sr. Manufacturing Engineer

Proterra-posted 8 days ago
Full-time • Mid Level
Greer, SC
501-1,000 employees
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The Manufacturing Engineer will be responsible for developing, implementing, and optimizing automated processes for the assembly of battery modules and packs. This role ensures that automated production lines consistently deliver high-quality, cost-effective, and safe products while supporting continuous improvement, scalability, and operational excellence in a high-volume manufacturing environment.

  • Process Engineering & Optimization Develop and validate automated processes for cell-to-module and module-to-pack assembly, including welding, fastening, sealing, potting, and end-of-line testing.
  • Define, document, and maintain process parameters, standard work instructions, and validation protocols.
  • Conduct PFMEA and implement poka-yoke/error-proofing systems to ensure process robustness.
  • Perform capability studies (Cp/Cpk), MSA, and DOE to optimize line performance and reduce variation.
  • Automation & Equipment Work with automation engineers and vendors to specify, install, and validate robotic assembly systems, conveyors, torque tools, and inspection equipment.
  • Support integration of MES, vision systems, leak tests, HiPot, and isolation resistance testers for real-time quality control.
  • Lead troubleshooting and root cause analysis for equipment and process issues, driving permanent corrective actions.
  • Quality & Compliance Ensure compliance with automotive/energy industry standards (IATF 16949, ISO, UL, etc.).
  • Partner with Quality to investigate nonconformities and drive corrective/preventive actions.
  • Support validation and approval of new materials, tooling, and equipment for production readiness.
  • Continuous Improvement Apply Lean Manufacturing and Six Sigma principles to improve OEE, yield, and throughput.
  • Lead kaizen events focused on cycle time reduction, ergonomic optimization, and scrap reduction.
  • Drive automation enhancements aligned with Industry 4.0, including data-driven process monitoring and predictive maintenance.
  • Collaboration & Training Work closely with Design Engineering to ensure DFM/DFA for cells, modules, and pack designs.
  • Collaborate with Maintenance, Controls, and Production teams to maintain line reliability and uptime.
  • Provide technical training to operators, technicians, and engineers on new processes and equipment.
  • Bachelor’s degree Mechanical, Manufacturing, Electrical, or Industrial Engineering (Master’s preferred).
  • 3–7 years of experience in automated high-volume manufacturing (battery, EV, automotive, or electronics strongly preferred).
  • Strong knowledge of module and pack assembly processes: cell handling, welding (laser/ultrasonic), fastening, sealing, thermal management integration, and EOL testing.
  • Hands-on experience with automated torque tools (e.g., Atlas Copco), robotics, PLCs, and vision inspection systems.
  • Proficiency with CAD, MES systems, and statistical analysis tools (Minitab, JMP, etc.).
  • Strong problem-solving, root cause analysis, and project management skills.
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