Senior Manufacturing Engineer
Confirmed on the employer's own hiring board on Oct 13, 2026. First seen by Alion on Sep 26, 2026.
EnerSys Advanced Systems (EAS) is a specialized division of EnerSys-a global leader in stored energy solutions for industrial applications. EAS focuses on cutting-edge energy solutions for the aerospace, defense, and medical industries. As we continue to grow, we’re looking for individuals who share a passion for these industries and want to be part of an innovative, dynamic team.
Certain positions at EnerSys Advanced Systems require access to information or technology that is subject to the International Traffic in Arms Regulations (ITAR) and other U.S. government security regulations. Candidates for these positions should be a “U.S. Person” under ITAR (U.S. citizen, lawful permanent resident, or a refugee/asylee) and/or otherwise comply with ITAR requirements for access rights to be considered for a position.
What We Offer:
- Generous Time Off - 3+ weeks of paid time off, plus 11 paid holidays
- Comprehensive Benefits - Medical, dental, and vision coverage for employees and dependents at a discounted rate
- Financial & Career Growth - Life insurance, short-term disability, educational reimbursement, flexible spending accounts, and an employee stock purchase plan
- 401(k) Matching - 100% match at a 6% contribution level
- Innovative Culture - We value excellence, teamwork, and long-term relationships with stakeholders, colleagues, and customers. Through innovative technology and ongoing training, we invest in our employees’ skills and career development.
At EAS, we don’t just build batteries - we power systems and devices that protect not only individual citizens but communities across the world.
If you’re excited about working in an innovative, fast-paced, high-tech environment, where your contributions make a real impact, we’d love to hear from you!
Compensation Range: $110,000 to $130,000 per year.
Compensation may vary based on applicant's work experience, education level, skill set.
Job Purpose
The Senior Manufacturing Engineer at Bren-Tronics, part of EnerSys and manufacture of advanced power solutions, is a key technical leader responsible for developing, optimizing, and sustaining manufacturing processes for battery production in a defense environment. This role focuses on driving operational excellence through advanced failure analysis, continuous process improvement, and rigorous adherence to military-grade quality standards. The Senior Manufacturing Engineer will ensure efficient process transitions, maintain product integrity, reduce production costs, and uphold strict compliance with defense manufacturing protocols.
Essential Duties and Responsibilities
- Serve as the primary manufacturing representative on cross-functional engineering teams to lead and coordinate the smooth transition of new defense battery products from design to production.
- Design, organize, and continuously improve battery assembly areas to meet evolving product specifications, Department of Defense (DoD) requirements, and production throughput goals.
- Lead initiatives to streamline and optimize manufacturing workflows, enhancing product quality, reducing cycle time, minimizing scrap, and maximizing output.
- Define requirements for specialized production equipment, tooling, fixtures, and test setups specific to high-reliability, mission-critical battery manufacturing.
- Drive compliance with defense quality standards (e.g., MIL-STD, AS9100, IPC) across all manufacturing processes and work instructions.
- Develop and deliver technical training to production teams to ensure full compliance with documented procedures, quality standards, and engineering requirements.
- Manage manufacturing engineering and act as a subject matter expert for battery-specific manufacturing processes, materials, and technologies.
- Support audits, customer inspections, and quality assurance activities as needed to maintain defense manufacturing certifications.
- Determine the requirements for equipment, tools, fixtures and fulfill real-time production needs for our manufacture operations.
- Monitor rework and repair operations, consistently monitor and report yield issues, and regularly highlight significant findings.
- Conduct failure analysis, identify root causes, and pursue effective solutions to minimize in-process defects.
- Other duties as assigned.
Qualifications
- Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Electrical Engineering, or a related technical field.
- 10+ years of experience in manufacturing engineering, with 3+ years specifically in battery production, defense manufacturing, or other mission-critical industries strongly preferred.
- Strong knowledge of battery technologies, including cell assembly, electrode processing, electrolyte handling, welding, sealing, environmental testing, chargers and accessories.
- In-depth experience with root cause analysis methodologies (e.g., 5 Whys, Fishbone Diagram, FMEA) and corrective action implementation (CAPA).
- Hands-on experience with designing and optimizing manufacturing processes, production lines, tooling, and fixtures.
- Familiarity with defense manufacturing standards and compliance requirements (e.g., MIL-STD, AS9100, ITAR).
- Proficient in statistical process control (SPC), lean manufacturing, Six Sigma tools, and continuous improvement principles.
- Ability to read and interpret engineering drawings, schematics, specifications, and work instructions.
- Strong technical writing skills to create clear work instructions, reports, and standard operating procedures (SOPs).
- Excellent communication skills, with the ability to work collaboratively in cross-functional teams.
General Job Requirements
- Generic
EnerSys provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws.
We use artificial intelligence to screen, assess and select applicants for open positions, including for the purposes of reviewing and ranking application materials and scoring answers to application questions. Accordingly, decisions about your application and eligibility for employment with EnerSys may be made based exclusively on the automated processing of the personal information that you submit in your application materials.