Sr. Process Engineer

AESC•Columbia, SC

1d•Onsite

About The Position

AESC is looking for a Senior Process Engineer to join their team in Columbia, SC. This role is the technical lead for AESC’s repack operation, responsible for designing, stabilizing, and continuously improving processes for battery module inspection, rework, repackaging, and outbound fulfillment. The position requires engineering rigor, process discipline, material flow, traceability, and cycle time efficiency, all of which are tied to customer commitments and site profitability. This role is also structured for an engineer with the ambition to grow into engineering management, involving mentoring junior engineers and technicians, leading cross-functional initiatives, and building leadership presence and operational judgment.

Requirements

Bachelor’s degree in Industrial, Electrical, Mechanical, or Chemical Engineering.
7+ years of process engineering experience in a high-volume manufacturing or distribution/fulfillment environment, with direct ownership of production processes, quality systems, and continuous improvement initiatives; experience in repack, kitting, rework, or value-added operations is strongly preferred.
Demonstrated mastery of structured problem-solving methodologies (8D, RCA, FMEA, DOE) with a track record of resolving chronic process issues and sustaining results; ability to coach others through these frameworks.
Proficient in Microsoft Office applications, AutoCAD, and Inventor.
Proven ability to manage multiple concurrent engineering projects from initiation through close, including capital equipment commissioning, new product introduction, and process improvement initiatives; comfortable setting priorities and holding timelines in a fast-paced environment.
Familiarity with battery module or pack handling, storage requirements, and safety protocols is an advantage; candidates from adjacent industries involving high-mix, low-volume, or inspection-intensive operations are also well-positioned for this role.
Self-directed and highly organized, with the ability to manage competing priorities independently while keeping cross-functional stakeholders informed; demonstrated willingness to take ownership and drive closure without waiting for direction.
Experience managing contractors, suppliers, and external engineering resources through the full project lifecycle, from RFP and vendor selection through commissioning and production start-up.
Strong communicator with the confidence to present technical findings and recommendations to senior leadership; able to adapt style for operators, engineers, and executives alike, and to influence decisions without direct authority.
Proficient in Microsoft Office (Excel, PowerPoint), AutoCAD, and data reporting tools; experience building dashboards or structured reporting that plant leadership can act on.
Experience standing up or significantly restructuring a repack, rework, or value-added operation, including developing work cell layouts, labor standards, and process documentation from early stages; comfort building structure in environments where processes are still being defined.
Demonstrated ability to lead through influence in cross-functional settings and an expressed interest in growing into engineering management; candidates who have informally mentored peers, led project teams, or taken on coordination responsibilities are encouraged to highlight that experience.
Understands and follows all standards of IATF 16949 and VDA 6.3 quality standards. (Training and awareness will be provided for those who are not familiar with these standards)
Understands and follows all standards of ISO 14001 environmental standards. (Training and awareness will be provided for those who are not familiar with these standards)
Understands and follows all standards of IATF16949 and VDA 6.3 quality standards. (training and awareness will be provided for those who are not familiar with these standards)
Understands and follows all standards of ISO14001 environmental standards. (training and awareness will be provided for those who are not familiar with these standards)

Nice To Haves

Prior experience formally or informally leading other engineers, technicians, or project teams; a clear interest in growing into an engineering management role and the self-awareness to articulate what that path looks like for you.
Hands-on involvement in new plant construction, retooling, or capacity expansion, with a working understanding of how to build and stabilize processes in environments where systems and standards are still maturing.
PMP or equivalent; or demonstrated application of formal project management methodology on capital or NPI programs.
Green Belt or Black Belt, with applied project experience; candidates who have led kaizen events or VSM initiatives in a production environment are particularly well-positioned.
Exposure to lithium-ion battery handling, warehouse management systems (WMS), serialization/traceability requirements, or OEM-driven packaging standards within an automotive or energy storage supply chain.
Working proficiency in PFMEA, Control Plans, MSA, and DOE; experience applying these tools in a production launch or process validation context rather than purely in a design or quality assurance role.
Japanese, Mandarin, or Spanish language skills are a plus given the global nature of AESC’s operations and supplier base.

Responsibilities

Own the end-to-end process for assigned repack work cells, including disassembly, inspection, rework, repackaging, labeling, and kitting; define and maintain control parameters, monitor throughput and quality KPIs, and drive sustained improvements in cycle time, first-pass yield, and material utilization.
Lead root cause investigations for process escapes, rework defects, material handling failures, and quality deviations using structured methodologies (8D, RCA, FMEA); develop corrective and preventive actions and track effectiveness through sustained performance metrics.
Lead engineering scope for repack-specific capital investments, including material handling equipment, inspection fixtures, test stations, and packaging machinery; manage vendor qualification, FAT/SAT sign-off, and production readiness from procurement through steady-state operation.
Develop and maintain process control plans, work instructions, PFMEAs, and visual standards for repack work cells; ensure documentation is current, accurate, and written at a level that supports operator training and audit readiness under IATF 16949 and customer-specific requirements.
Identify and lead Kaizen events, line balancing exercises, and waste reduction initiatives focused on repack-specific losses — including excessive rework loops, material handling inefficiencies, and packaging variation; mentor junior engineers and technicians through improvement projects while building sustainable team capability.
Lead process engineering activities for new repack SKUs, customer program launches, and inbound product transitions; develop work cell layouts, time studies, and operator qualification plans that enable rapid, repeatable ramp-up with minimal quality risk.
Champion a culture of safety within the engineering team and on the plant floor; conduct process and safety audits, ensure engineering changes comply with applicable standards (IATF 16949, ISO 14001, OSHA), and actively participate in risk assessments for new processes and equipment.
Act as the engineering lead on cross-functional project teams, providing direction to contractors, technicians, and junior engineers; model collaborative problem-solving, set clear priorities, and develop the technical and professional skills of those around you as a precursor to formal people management responsibilities.
Use SPC, time studies, and line efficiency data to monitor repack process stability, identify variation sources, and validate improvement actions; build reporting that gives operations leadership clear, actionable visibility into cost-per-unit, rework rates, and throughput trends.
Prepare and present engineering updates, project status, and improvement results to plant leadership and senior management; communicate technical findings in a clear, structured manner that supports decision-making and builds confidence in the engineering team’s execution.
Complete other duties as assigned.

Benefits

Comprehensive compensation packages including a competitive salary and a rewarding bonus program.
An inclusive and diverse work environment that fosters and encourages professional and personal development.
Highly automated, clean, safe, and temperature-controlled production environment
Medical, Dental and Vision Insurance
HSA and Flexible Spending Accounts
401K with company match
Life Insurance (Company paid and additional voluntary life available)
Paid Vacation and 14 Paid Holidays
Short term and long-term disability coverage (Company Paid)
Tuition reimbursement