A123 Systems, Inc. Process Development Engineer-Coating (Electrode Build) in Waltham, Massachusetts


The R&D Process Development Engineer will support electrode material production activities of Waltham R&D product lines by supervising, improving, and maintaining manufacturing equipment and processes for mixing and coating operations. Support activities include equipment specification, tooling design, process optimization, and qualification. Also responsible for the conceptualization and development of new cell assembly processes and techniques to reduce cost, improve sustainability and develop best practices within the production process.


  • Coordinate electrode material fabrication operations including mixing, slurry preparation, and electrode coating and calendering.

  • Maintain electrode build pilot production line, overseeing production and quality control processes

  • Daily support for R&D electrode build team, providing guidance and instruction to operation technicians and QC staff

  • Measure and analyze process variables, use data to develop and implement continuous improvement plan for capability, cost, and efficiency of existing processes and equipment

  • Prepare product/process reports by collecting, analyzing, and summarizing information and trends

  • Create and maintain Standard Operation Procedure documentation

  • Utilize root cause analysis tools to identify and solve production issues

  • Assist in adjusting/updating machine settings and parameters for various product lines

  • Conceptualize and develop new processes to meet the needs of both internal and external customers by studying product requirements, researching, designing, and testing manufacturing methods and equipment

  • Research, commission, and validate new equipment as necessary

Specific Skills/Abilities

  • Internally driven to solve complex problems and take on new challenges

  • Strong analytical skills–interpret and make data driven decisions

  • Strong organizational and management skills – capable of leading technical projects

  • Ability to effectively communicate verbally and in writing in the form of technical reports

  • Passion for being hands-on – mechanical and electrical

  • Solid modeling skills preferred– Solidworks or Pro/E

  • Able to create and interpret mechanical drawings

  • Proficiency with Microsoft Office Suite (Word, Excel, Powerpoint) is required



  • S. in Mechanical, Chemical, or Industrial Engineering

  • 4 or more years of process engineering experience in a manufacturing environment

  • Experience with mixing operations, thin film coatings, in-process measurement technologies, and associated quality control metrics

  • Exposure to data acquisition equipment and software (LabView or other) preferred

Physical Demands and Work Environment

  • Capable of climbing stairs, lifting 20 kg or less

  • Able to work at nominal heights

  • Able to perform equipment maintenance tasks that may require bending, stooping, lying down or working from elevated platforms. Requires full use and range of motion of arms, hands and fingers to reach, grasp, hold, push or pull, twist, and work with tools

  • Must use appropriate PPE as required

ID 2016-1348

of Openings 1

Job Locations US-MA-Waltham

Posted Date 10/17/2016

Category Engineering