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Process Developent Engineer
Milwaukee , Wisconsin
March 01, 2017
Job Description:
Position Description:
  • The Sr. Process Development Engineer develops, executes, and evaluates processes and manufacturing methods for Li-Ion battery cells. Primary processing areas include mixing, coating, drying, and electrolyte filling.
  • The team member must operate with a good working knowledge of the chemical processes, equipment, exposure/safety protocols, and process control methods.
  • The role interacts heavily with other teams, including the electro-chemical design team, the manufacturing engineering equipment team, and the manufacturing operations team. Responsibilities include R&D trials and evaluations, equipment specification and commissioning, process capability and stabilization, and hands-on support of builds, trials, and equipment qualifications.
  • Scope of position covers the following: (1) Chemical Engineering, (2) Process Controls (3) Material & Process diagnostics, (5) Equipment maintenance & PMs, (6) Trial runs
  • Competency in the methods, procedures, and interpretation of results using Design of Experiments, Quality Assurance, Control Charting, and Six Sigma activities is desirable.

Typical Duties:
  • Oversees the development and execution of chemical processing at the JCI Battery Technology Center. Primary process include mixing, coating, drying, and filling for Li-Ion battery development.
  • Active, hands-on participation in trial run and build activities. Expectations are 40% hands-on participation for on the floor activities and 60% office work.
  • Design and execute DOEs for new materials and process optimization.
  • Monitoring, Recording, and Reporting of run data for all development activities.
  • Report out of project progress, trial results, and future schedules to management and extended teams.
  • Ensures product designs, manufacturing processes, and equipment specifications are developed with the highest capability for future production implementation.
  • Equipment specification, sourcing, installation, and prove-out for machinery and processes being installed into production sites.
  • Creation of PFMEA, Control Plans, Process Monitoring and other related documentation.
  • Continuous Improvement activities and quality problem solving activities for both the R&D sites and the production sites.
  • Support training and development for team members and area technicians.
  • Closely interact with both the Development teams (Milwaukee) and the Manufacturing Engineering team (Holland) on new products, product changes and verification, trial runs and DOEs.
  • Understanding and environmental control for nano-particle inhalation protection, hazardous materials and training to insure proper procedures are followed and enforced.
  • Interface and present to internal and external customers.

  • Milwaukee, WI. Johnson Controls Battery Technology Center.
Travel expectation is minimal, but availability to travel up to 25% travel is required. Travel may be domestic or international as required for site visits, vender interactions, equipment run-offs, and equipment installs

Job Qualifications:
  • BS in Chemical, Manufacturing, or Industrial Engineering.
  • 5+ years job experience in a related processing industry.
  • Previous experience in: mixing, thin film coating, material drying, web handling, and filling/metering required
  • Experience with Li-Ion battery manufacturing and/or development preferred.
  • Able to work in clean/dry rooms with chemicals and required protective gear.
  • Able to develop, follow, and propagate proper chemical handling and exposure control protocols.
  • Experience with automotive industry and quality standards is preferred. Including: AIAG, APQP, PPAP, ISO/TS
  • Analytical analysis such as Six Sigma, Kepner-Tregoe, and Robust Engineering is preferred.
  • Quality systems experience such as ISO/TS certification, SPC, MSA/Gage-R&R, and capability analysis is preferred

A little about us:
Johnson Controls is a global diversified technology and industrial leader serving customers in more than 150 countries.

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