Sr. Battery Manufacturing Engineer

Responsibilities

• This role is within the High Voltage Power Systems Manufacturing Engineering team that oversees the manufacturing of Battery Module/Pack and associated components, responsible from prototype through series production.
• Design, develop and deploy manufacturing lines for Battery Manufacturing at Archer facilities
• Define build sequence, process flow steps, cycle time, Layout, design for manufacturing and develop applicable Manufacturing process solutions.
• Support process failure mode and analysis (PFMEA).
• Develop Equipment specifications and work with suppliers through RFQ, PO, FAT/SAT, Onsite Installation, Equipment validation/Qualification and SOP.
• Prepare Budget and Project execution Schedule and financial justification for leadership reviews.
• Develop Factory Acceptance Testing plan and oversee the testing at various stages of the line development and launch.
• Drive process control, specifically in the areas of quality and equipment capability.
• Review and disposition quality notifications, including process non-conformances, determining appropriate corrective and preventive actions. Participate in the Material Review Board (MRB).
• Maintain and optimize Manufacturing Execution System (MES) configurations, including shop floor routings, process parameters, work instructions, and data collection protocols.
• Serve as process generalist and backup to process owners on production lines, providing technical support and troubleshooting during equipment downtime or process deviations.
• Identify and drive continuous improvement and cost reduction programs, optimize product flow and line efficiency by designing or improving tools, jigs, stations, work methods and ergonomics using the 5S methodology.
• Support operations on the shop floor, establish KPIs in order to drive performance management, identify trends and mitigate risks.
• What you need:
• BS or MS Degree in Engineering or a related field
• 3 + years of manufacturing experience preferably in EV battery module/pack manufacturing
• Strong hands-on experience with prototype and high-volume manufacturing
• Experience in working on capex projects from concept through commissioning.
• Have a demonstrated track record of Overall Equipment Effectiveness (OEE) improvement, Preventative and Predictive Maintenance activities.
• Experience in statistical process control, GD&T, and lean manufacturing concepts
• Proficiency in data analysis tools (Minitab, JMP, Python, or similar statistical software)
• Experience with failure analysis techniques and root cause analysis methodologies (8D, 5-Why, Fishbone)
• Knowledge of Safety Standards (ANSI/RIA15.06, OSHA)
• Experience with CAD, PLM, MES, and ERP software.
• Understanding of PLCs, robots, motion control devices, vision systems and human machine safety devices.
• Ability to travel domestically and internationally
• Bonus Qualifications:
• Experience with thermoplastic part joining (eg. ultrasonic welding)
• Understanding of aviation battery certification requirements (DO-311A, DO-160, RTCA standards)
• Experience with airworthiness requirements and aviation safety management systems
• Experience with aviation-grade traceability and configuration management
• Experience with FAR 23, Part 21, FAA Production Certification
• Please note that this job description is intended to provide a general overview of the position and does not include an exhaustive list of responsibilities and qualifications
• Archer is co

Benefits

Additional Information

Archer is an aerospace company based in San Jose, California building an all-electric vertical takeoff and landing aircraft with a mission to advance the benefits of sustainable air mobility. We are designing, manufacturing, and operating an all-electric aircraft that can carry four passengers while producing minimal noise. Our sights are set high and our problems are hard, and we believe that diversity in the workplace is what makes us smarter, drives better insights, and will ultimately lift us all to success. We are dedicated to cultivating an equitable and inclusive environment that embraces our differences, and supports and celebrates all of our team members.

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