Senior Staff Customer Quality Engineer
In this highly visible role, you will have the opportunity to make a significant impact on next-generation battery products and establish quality systems that scale from development through high-volume production. You will serve as the critical bridge between our internal cell engineering and product teams and the factory floor—enabling the reliable, high-yield manufacture of advanced battery cells.
Responsibilities and Duties
Manage IQC, IPQC, OQC, and ORT across battery cell production lines
Drive quality readiness at the Contract Manufacturer (CM) for development builds (EVT/DVT/PVT) and mass production ramp, including establishing inspection and hold/release protocols
Lead root cause and corrective action (RCCA) investigations for quality escapes; present findings and closure plans to internal and CM leadership as required
Collaborate with cell engineering and teams to define and implement appropriate quality control, inspection, and metrology stations across the full cell production process (electrode coating and calendering, winding/stacking, electrolyte filling, formation, aging, and final test)
Define and monitor electrochemical quality metrics, identify process signals and drive SPC implementation
Conduct periodic factory quality reviews covering yield, scrap, defect Pareto, and process capability trends
Prepare OK-to-Ship and lot dispositioning documentation for new product launch and ongoing mass production
Develop and maintain risk assessments (PFMEA) for battery manufacturing processes; implement control plans and reaction plans for identified risk items
Support DFM reviews with cell design and product teams; conduct tolerance analysis for electrode stack, cell can/pouch dimensions, and assembly fit to ensure process capability against specification
Develop and execute module and cell reliability test plans (cycle life, calendar aging, thermal abuse, mechanical) during NPI and MP, in coordination with internal engineering teams
Ensure manufacturing process controls are sufficient to maintain compliance with applicable safety and certification standards (IEC 62133, UN 38.3, UL 1642, GB/T equivalents as applicable) at the production level
30–40% international travel to CM sites in Asia required
Knowledge and Skill Requirements
Minimum of 12 years of related experience with a Bachelor’s degree; or 8 years and a Master’s degree; or a PhD with 5 years experience; or equivalent experience.
Hands-on experience in lithium-ion cell manufacturing processes and product qualification
Familiarity with battery-specific metrology: coating weight, electrode thickness and density, porosity, tab alignment, and electrolyte fill weight measurement and control
Strong command of quality and problem-solving tools: DOE, RCCA/8D, SPC, GR&R/MSA, PFMEA, control plans, and capability analysis (Cpk/Ppk)
Knowledge of reliability methods relevant to batteries: Weibull analysis, HALT/HASS, accelerated life testing, and electrochemical failure mode characterization
Familiarity with GD&T, tolerance stack-up analysis, and metrology best practices in a precision manufacturing context
Experience managing CM/OEM quality relationships in Asia; ability to navigate cultural and organizational dynamics effectively
Track record of developing manufacturing process documentation that captures process rationale, critical control points, failure modes and equipment constraints.
Working knowledge of battery safety standards and certification pathways (IEC, UL, GB/T, KC, PSE)
Strong cross-functional communication skills; comfortable presenting technical findings to engineering and executive audiences
Physical Demands and Working Conditions
Operate a computer and other office equipment, such as a laptop, copier/printer, etc in a fixed location
The starting base pay for this role is between $156,000 and $197,000 at the time of posting. The actual base pay depends on many factors, such as education, experience, and skills. Base pay is only one part of Sila’s competitive Total Rewards package that can include benefits, perks, equity, and bonuses. The base pay range is subject to change and may be modified in the future.
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