Associate Director, Module & Pack Rework

Position Summary

We are seeking an experienced Associate Director, Module & Pack Rework, to lead the end-to-end rework, repair, recovery, testing, and disposition of lithium-ion battery modules and packs. This role will build and manage a safe, standardized, scalable, and data-driven rework operation supporting high-volume battery manufacturing.

The ideal candidate brings strong manufacturing leadership, battery module/pack knowledge, quality systems expertise, technical troubleshooting, and continuous improvement experience. This position partners across Manufacturing, Engineering, Quality, Maintenance, Planning, Logistics, EHS, and suppliers to maximize recovery, reduce scrap, improve throughput, and prevent recurring defects.

Key Responsibilities

• Lead all Module and Pack rework operations, including defect evaluation, repair, validation testing, quality release, and final disposition.
• Build and scale the rework organization, including staffing, equipment, capacity planning, workflows, and operating strategy.
• Establish standardized procedures, repair limits, quality standards, traceability, escalation paths, and controls for nonconforming product.
• Own daily performance across safety, quality, delivery, cost, inventory, recovery rate, cycle time, and throughput.
• Analyze defect and performance data, drive corrective actions, and provide regular updates to leadership.

Rework Process & Quality Management

• Develop and continuously improve standardized rework processes for diagnosis, component replacement, electrical/mechanical repair, software verification, validation testing, and final release.
• Ensure reworked products meet the same safety, quality, reliability, and functional requirements as standard production units.
• Partner with Quality to define acceptance criteria, repair limits, scrap thresholds, MRB disposition, deviations, and concessions.
• Establish defect tracking and reporting systems to measure repair effectiveness, reliability, recurrence, and recovery performance.
• Lead root cause investigations, 8D/CAPA activities, and closure of recurring manufacturing and quality issues.

Manufacturing & Engineering Coordination

• Lead cross-functional troubleshooting of Module and Pack manufacturing defects and drive corrective actions across processes, equipment, tooling, and production controls.
• Support diagnostic, automation, testing, MES, and traceability solutions that improve rework efficiency and decision-making.
• Partner with internal teams and equipment suppliers to resolve technical issues and support production launches and ramp-ups.

Continuous Improvement & Cost Reduction

• Reduce scrap, rework cost, and Cost of Poor Quality (COPQ) by prioritizing high-impact defect and manufacturing loss reduction.
• Improve yield, recovery rate, cycle time, labor efficiency, equipment uptime, and defect recurrence through Lean and data-driven improvement.
• Optimize workflow, material flow, tooling, and repair methods; quantify savings and drive long-term defect elimination at the source.

Production, Workforce & Material Control

• Build, lead, and develop a high-performing rework team with clear staffing plans, production targets, roles, responsibilities, and escalation processes.
• Develop training and qualification programs for battery rework, troubleshooting, quality standards, and safe work practices.
• Coordinate identification, segregation, traceability, storage, inventory, and movement of nonconforming products, replacement parts, and repair materials.
• Foster a culture of safety, accountability, teamwork, ownership, and continuous improvement.

Safety & Compliance

• Ensure all rework activities comply with EHS, regulatory, and company requirements.
• Establish and enforce safe practices for lithium-ion battery handling, electrical safety, LOTO, PPE, and hazardous material controls.
• Partner with EHS on risk assessments, controls, and personnel qualification for battery rework operations.

Required Qualifications

• Bachelor's degree in Engineering, Manufacturing, Operations, or a related field.
• 5+ years of manufacturing, engineering, quality, or operations experience, including leadership responsibility.
• Strong experience in manufacturing operations, technical troubleshooting, process improvement, and quality systems.
• Demonstrated ability to lead teams and deliver results in a fast-paced production environment.

Technical Skills

• Knowledge of lithium-ion battery systems, manufacturing processes, testing, and safety.
• Experience with automated equipment, PLC/HMI systems, robotics, MES, and traceability systems.
• Proficiency in Root Cause Analysis, 8D, PFMEA, CAPA, Lean Manufacturing, and continuous improvement tools.

Core Competencies

• Leadership and team development
• Problem-solving and decision-making
• Cross-functional collaboration
• Continuous improvement
• Safety / Quality / Delivery / Cost ownership
• Data-driven execution

Preferred Qualifications

• Experience in battery, EV, automotive, energy storage, or other high-volume manufacturing environments.
• Experience with battery Module/Pack production, rework operations, production line launches, or manufacturing scale-up.
• Lean Six Sigma, PMP, or similar certification preferred.

 

The U.S. base salary range for this full-time position is $158,000.00- $178,000.00 plus eligibility for 20% bonus and benefits. Our salary ranges are determined by factors such as the role, level, and geographic location. The range listed in the job posting represents the minimum and maximum target salaries for this position across all U.S. locations. Actual compensation within the range will be influenced by the specific work location, along with factors such as job-related skills, experience, and relevant education or training. Your recruiter will provide more details about the specific salary range for your preferred location during the hiring process. Please note that the listed compensation reflects the base salary only and does not include bonus or benefits.