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.

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.