Job PurposeThe 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 
