Note: The job is a remote job and is open to candidates in USA. ON.energy is building the power infrastructure that makes the AI era possible, providing a new class of power technology trusted by leading cloud and AI companies. The Senior Manufacturing Engineer will own the design-to-line translation for integrated products, defining assembly processes and driving continuous improvement in manufacturing efficiency.
Responsibilities
- Develop and document manufacturing processes, assembly sequences, and standard work instructions for BESS enclosures, DC subsystems, power conversion systems (PCS), and medium-voltage UPS/microgrid assemblies
- Lead Design for Manufacturing and Assembly (DFMA) reviews with product and design engineering to improve manufacturability, reduce part count, and drive down cost before designs are released
- Define and validate station-level requirements: workstations, tooling, fixtures, torque and crimp specs, cabling and busbar routing, and material flow across the line
- Establish production readiness and manufacturing-readiness milestones for new products and product changes, including in-process (IPQC) and end-of-line (EOL) test checkpoints
- Specify and commission functional and safety test procedures — insulation/dielectric (hipot), continuity, BMS communication, PCS/UPS functional test, and integration with On.Command™ controls and telemetry
- Partner with contract manufacturers on process transfer, first-article inspection (FAI), production ramp, and ongoing process control; travel to CM and field sites as needed
- Drive root-cause analysis (8D, 5-Why, fishbone) on quality escapes and line stoppages, and implement corrective/preventive actions
- Lead continuous-improvement initiatives using Lean and Six Sigma methods (value-stream mapping, kaizen, SPC) to improve yield, throughput, and cost per unit
- Own engineering change management (ECN/ECO) from the manufacturing side, including bill-of-material (BOM) accuracy, routings, and configuration control in the ERP/PLM system
- Support production capacity planning, line balancing, and takt-time analysis to meet build schedules
- Champion a safety-first culture on the floor: LOTO, arc-flash and high-voltage/medium-voltage safe work practices, and ergonomic workstation design
Skills
- Bachelor's degree in Mechanical, Electrical, Manufacturing, or Industrial Engineering (or equivalent experience)
- 3+ years of manufacturing/process engineering experience with electromechanical products — energy storage, power electronics, UPS, switchgear, electric vehicle, or similar high-voltage/high-power hardware strongly preferred
- Hands-on knowledge of assembly processes for electrical cabinets and enclosures: wiring/harnessing, busbar and cable termination, connectorization, and panel build
- Working understanding of power systems fundamentals — DC battery systems, PCS/inverters, and AC power distribution/UPS — and the safety practices that go with them
- Proficiency with DFMA principles, GD&T, and reading electrical schematics and mechanical drawings
- Experience creating work instructions, process FMEAs, control plans, and test procedures
- Familiarity with Lean Manufacturing and Six Sigma (Green Belt or higher a plus)
- Experience working in an ERP/PLM environment (e.g., SAP, Oracle, Arena, Windchill) for BOMs, routings, and change control
- Strong problem-solving skills, disciplined documentation habits, and the ability to work cross-functionally across engineering, quality, supply chain, and operations
- Willingness to travel (typically up to ~25%) to contract manufacturers, suppliers, and project/field sites
- Experience with battery module/pack integration, BMS interfaces, and thermal management
- Experience with medium-voltage equipment and microgrid or UPS integration
- Knowledge of relevant standards: UL 9540 / UL 9540A, UL 1741, IEC 62933, NFPA 70/70E, and applicable UPS standards (e.g., UL 1778 / IEC 62040)
- Experience standing up a new production line or transferring a product to a contract manufacturer
- Familiarity with test automation, data acquisition (e.g., LabVIEW), and EOL test system development
Benefits
- Annual performance-based bonus eligibility
- Medical, dental, and vision insurance
- 401(k) with company match
- Paid time off and company holidays
- Christmas Bonus (Aguinaldo): 30 days
- Major medical expenses and life insurance
- Paid time off and holidays (per local policy)
- Professional development and growth opportunities
Company Overview