Job Title:  Senior Manufacturing Engineer

Job Purpose

The Senior Manufacturing Engineer at Bren-Tronics, part of EnerSys and manufacture of advanced power solutions, is a key technical leader responsible for developing, optimizing, and sustaining manufacturing processes for battery production in a defense environment. This role focuses on driving operational excellence through advanced failure analysis, continuous process improvement, and rigorous adherence to military-grade quality standards. The Senior Manufacturing Engineer will ensure efficient process transitions, maintain product integrity, reduce production costs, and uphold strict compliance with defense manufacturing protocols.

Essential Duties and Responsibilities

• Serve as the primary manufacturing representative on cross-functional engineering teams to lead and coordinate the smooth transition of new defense battery products from design to production.
• Design, organize, and continuously improve battery assembly areas to meet evolving product specifications, Department of Defense (DoD) requirements, and production throughput goals.
• Lead initiatives to streamline and optimize manufacturing workflows, enhancing product quality, reducing cycle time, minimizing scrap, and maximizing output.
• Define requirements for specialized production equipment, tooling, fixtures, and test setups specific to high-reliability, mission-critical battery manufacturing.
• Drive compliance with defense quality standards (e.g., MIL-STD, AS9100, IPC) across all manufacturing processes and work instructions.
• Develop and deliver technical training to production teams to ensure full compliance with documented procedures, quality standards, and engineering requirements.
• Manage manufacturing engineering and act as a subject matter expert for battery-specific manufacturing processes, materials, and technologies.
• Support audits, customer inspections, and quality assurance activities as needed to maintain defense manufacturing certifications.
• Determine the requirements for equipment, tools, fixtures and fulfill real-time production needs for our manufacture operations.
• Monitor rework and repair operations, consistently monitor and report yield issues, and regularly highlight significant findings.
• Conduct failure analysis, identify root causes, and pursue effective solutions to minimize in-process defects.
• Other duties as assigned.

Qualifications

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Electrical Engineering, or a related technical field.
• 10+ years of experience in manufacturing engineering, with 3+ years specifically in battery production, defense manufacturing, or other mission-critical industries strongly preferred.
• Strong knowledge of battery technologies, including cell assembly, electrode processing, electrolyte handling, welding, sealing, environmental testing, chargers and accessories.
• In-depth experience with root cause analysis methodologies (e.g., 5 Whys, Fishbone Diagram, FMEA) and corrective action implementation (CAPA).
• Hands-on experience with designing and optimizing manufacturing processes, production lines, tooling, and fixtures.
• Familiarity with defense manufacturing standards and compliance requirements (e.g., MIL-STD, AS9100, ITAR).
• Proficient in statistical process control (SPC), lean manufacturing, Six Sigma tools, and continuous improvement principles.
• Ability to read and interpret engineering drawings, schematics, specifications, and work instructions.
• Strong technical writing skills to create clear work instructions, reports, and standard operating procedures (SOPs).
• Excellent communication skills, with the ability to work collaboratively in cross-functional teams.

General Job Requirements