Role SummaryAs the site-level NPI execution lead for battery cell development and mass production transfer projects led by Headquarters NPI/R&D in South Korea, this role is responsible for end-to-end on-site execution from pilot line validation to mass production stabilization. In alignment with HQ guidelines, the NPI Engineer will collect cell assembly process data, support customer PPAP approval, stabilize initial production yield, and optimize process parameters.
Responsibilities- New Cell Line Transfer & Ramp-Up Support: Execute pilot runs and DV/PD/PV (Design/Process Development/ Production Validation) sample builds according to HQ R&D/NPI schedules.
- Assembly Process Parameter Validation: Validate process recipes and parameter settings (welding conditions, electrolyte amount, pressing force, etc.) transferred from HQ.
- Analyze data variance across equipment/lines and provide engineering feedback to HQ R&D.
- Project Gate Review Support: Prepare and share line uptime, cell yield, and bottleneck analysis reports required for NPI Gate Reviews.
- PPAP Data Collection & Package Support: Collect and submit assembly process capability data (Cpk/Ppk), Gauge R&R, and MSA data as requested by HQ Quality/Customer Support teams.
- Site Quality Documentation Alignment: Localize and update site-specific PFMEAs, Standard Operating Procedures (SOPs), and inspection standards based on HQ standard documents (DFMEA/PFMEA, Control Plan).
- Customer On-Site Audit Support: Lead line tours, demonstrate key assembly/inspection processes during customer audits, and implement corrective actions for audit findings.
- Initial Yield & Cpk Management: Monitor ramp-up yield trends, conduct Pareto analysis on defect types and control process variation to achieve target capability for key assembly processes.
- Issue 8D reports for NPI stage defects including tab welding failures, dimensional/visual defects, and sealing/leakage issues and conduct root cause investigations using cross-sectional analysis, reporting findings to HQ
- Process Parameter Optimization: Optimize laser welding parameters, electrolyte injection/soaking time, and humidity/pressure controls to reduce defect rates.
- Transfer validated assembly process know-how, safety guidelines, and operating precautions to site manufacturing and quality teams.
- Document and manage approvals for 4M (Man, Machine, Material, Method) changes occurring during the NPI phase.
Basic Qualifications- Bachelor's degree or higher in Engineering (Chemical, Materials, Mechanical, Electrical, or related fields).
- Minimum 7 years of experience in NPI, Process Engineering, or Quality Engineering in manufacturing.
- Technical Competencies including:
- Hands-on experience in generating PPAP documentation and datasets (PFMEA, Control Plan, MSA, Cpk/Ppk).
- Problem-solving skills for shop-floor issues such as 8D Report or 5-Why methodology
- Proficiency in statistical data analysis tools (Minitab, SPC).
Preferred Qualifications- Battery Cell Assembly Experience (Highly Preferred)
- Language & Communication: Professional working proficiency in English (both verbal and written) for cross-functional collaboration with HQ and global clients.
- Understanding of quality systems such as Six Sigma, DOE, and statistical tools.
- Project & Quality System Experience:
- Experience in HQ-to-plant tech transfer projects for new battery cell products.
- Experience in customer PPAP submission and audit response under IATF 16949 quality standards.
