Process Engineer

2 months ago

Kingston, United States HSAGP Energy Full time

HSAGP(Hyundai-SK America Green power) Energy LLC. is Hyundai Motor Group and SK on' s joint venture company to produce batteries for EVs.


The joint venture plans to invest $5 billion to build an EV battery cell plant in Bartow County, Georgia. Hyundai Motor Group and SK On will each hold a 50 percent stake in the joint venture.


The new plant created by the two companies is expected to start manufacturing battery cells in the first half of 2026 with an annual production capacity of 35 GWh, enough to support the production of 300,000 EVs a year.


The future Bartow County plant in northwest Georgia is strategically located near Hyundai Motor Group’s existing and planned U.S. facilities. Hyundai Motor Group broke ground last year on the new Hyundai Motor Group Metaplant America in southeast Georgia to make future Hyundai, Genesis and Kia EVs.


Join us on the journey of two companies' massive electric vehicle project in Bartow County.


Summary of this Job

Battery manufacturing is composed of electrode, assembly and formation processes. In the Electrode process, raw materials are mixed and coated on to foils to make electrode sheets. Then, electrode components are stacked, welded and packaged in a cell housing during the Assembly process. Finally, through the Formation process the assembled cell is activated with electric energy and tested to evaluate its performance and characteristics.

Battery process engineer is responsible for work that includes but not limited to monitoring, analyzing, and reporting of production results, and ensuring high yield and productivity for each electrode, cell assembly and formation process by implementing and improving manufacturing methods and processes. This position will also need to interact with other teams and vendors to solve complex and/or urgent problems by identifying and evaluating alternatives or by providing needed information and advice. As working on a 24/7 facility, this position may require on-call support in various circumstances. Candidates should be motivated problem solvers that can provide creative solution approaches to your task with concern about effectiveness and quality that are well based in the technology expertise and best practices.


Electrode

  • Mixing: The active materials are mixed by combining the processed metal oxides with a conductive additive and a binder
  • Coating: This mixture is called a slurry which is then coated onto metal foil sheets, typically aluminum or copper
  • Pressing: To press the coated electrode materials. Pressing removes excess solvents and improves the density, adhesion
  • Slitting: The machine uses sharp blades or rotary cutters to slice the sheet into narrower strips or ribbons of the desired width


Assembly

  • Notching: Refers to the process where reel of electrode is cut into individual sheets with designed dimensions
  • Vacuum Drying: Vacuum drying removes moisture from sheets of electrodes to ensure low moisture content in assembled battery cells
  • Stacking: The cathode and anode foils are stacked together with a separator material in between to create a jelly roll-like structure.
  • Tab welding: Tab welding connects a set electrode foils to tab.
  • Packaging: The purpose of packaging is to place Jelly roll into formed pouch, fill with electrolyte and seal


Formation

  • Pre-Charging: It is the initial charging process performed on a newly assembled battery pack.
  • Degassing: It is a critical step that helps remove any excess or volatile gasses that may have accumulated within the battery cells.
  • Aging: A controlled procedure where the battery cells are subjected to specific conditions to simulate their performance over time.
  • Inspection: In inspection the battery cells undergo final testing to ensure they meet the required performance and quality standards.


Key Areas of Responsibility:

  • Troubleshooting and solutions: Identify and resolve issues in processes, product quality, and equipment by developing effective solutions.
  • Data analysis: Examine production raw data to conduct defect analysis, determine root causes, and implement corrective actions.
  • Performance improvement: Monitor and enhance yield, overall equipment efficiency (OEE), and parts per million (PPM) in electrode, assembly, and formation production processes.
  • Compliance Monitoring: Oversee operating conditions at each production stage to ensure adherence to process regulations and address malfunctions.
  • Technical Expertise: Provide technical support to ensure production aligns with quality, efficiency, and safety standards, including preparation for production runs, oversight during production, and managing changes in instructions or materials.
  • PFMEA (Process Failure Mode and Effects Analysis) Management: Regularly review and update Process Failure Mode and Effects Analysis (PFMEA).
  • Reporting: Communicate key production activities, results, and indicators on a daily or weekly basis.
  • Team Collaborations: Work collaboratively with Engineers, Supervisors, and Operators to achieve production milestones.
  • Training: Prepare and update work instructions, and provide training for new employees.
  • Continuous Improvement: Enhance the production environment using 5S (Sort, Set in Order, Shine, Standardize, Sustain) and 3R (Right Material, Right Quantity, Right Position) standards.
  • IT Systems: Utilize production-related IT systems such as MES and other data verification tools effectively.


Required Qualifications:

  • Education: Bachelor’s degree or higher in Mechanical Engineering, Electrical Engineering, Chemical Engineering, or a related field
  • Experiences: 3+ years in high-volume manufacturing, preferably within the battery or related industry


Preferred Qualifications:

  • Battery manufacturing experience
  • Manufacturing experience related to the process of batteries (mixing, coating, slitting, notching, stacking, welding, packaging, and degassing)

Skills

  • Knowledge of battery production processes and equipment
  • Proficiency in data analysis and statistical methods
  • Familiarity with IT systems related to manufacturing, including MES and data verification tools
  • Problem-solving and troubleshooting skills
  • Effective communication and teamwork abilities
  • Strong attention to detail and commitment to quality

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