Formation Engineer

Job Description Formation Engineer (Li-Ion Battery Manufacturing) Role Summary The Formation Engineer will be responsible for managing and optimizing the battery cell formation, aging, and grading processes to ensure product quality, performance, and manufacturing efficiency. The role involves process monitoring, troubleshooting, yield improvement, and collaboration with cross-functional teams to support high-volume lithium-ion battery production. Key Responsibilities Monitor and optimize Formation, Aging, Degassing, and Grading processes to achieve quality, yield, and productivity targets. Develop and implement process parameters, SOPs, and work instructions for formation operations. Analyze process data to identify trends, improve cycle efficiency, and reduce process variations. Investigate process abnormalities and lead root cause analysis using tools such as 8D, 5 Why, and Fishbone. Support process validation, equipment qualification, and production ramp-up activities. Collaborate with Manufacturing, Process Engineering, Quality, Equipment, Maintenance, and R&D teams to resolve production issues. Monitor key KPIs including yield, cycle time, OEE, energy consumption, and defect rates. Drive continuous improvement initiatives using Lean Manufacturing, Six Sigma, and Kaizen methodologies. Ensure compliance with EHS, quality standards, and manufacturing procedures. Support new product introduction (NPI) and continuous process optimization. Qualifications Bachelor's degree in Chemical Engineering, Electrical Engineering, Mechanical Engineering, Materials Science, or a related discipline. Lean Six Sigma certification is preferred. Experience 3–8 years of experience in lithium-ion battery manufacturing, preferably in Formation, Aging, or Cell Finishing processes. Experience in high-volume manufacturing and factory ramp-up is an added advantage. Technical Skills Strong understanding of lithium-ion cell formation, aging, grading, and electrochemical processes. Knowledge of formation equipment, charge/discharge profiles, and process optimization. Familiarity with SPC, PFMEA, CAPA, and quality improvement methodologies. Experience with MES, ERP systems, and data analysis tools such as Excel, Minitab, or Power BI. Strong analytical, troubleshooting, and cross-functional collaboration skills.