Quality Manager

Quality/Reliability Manager – Defect Analysis Part Lead

Full Time

Warren, OH, US

Ultium Cells Overview:

Ultium Cells is a joint venture Lithium-Ion Automotive Battery Cell Manufacturing plant between LG Energy Solutions and General Motors. This new construction high-technology plant will have the latest Battery Cell manufacturing technology. The investment in this new business venture represents a commitment of more than $2.3 Billion.  It will be among the largest Battery Cell Manufacturing plants in the world. Ultium Cells will produce battery cells for General Motors North American electric vehicle applications.  

The Ultium cell partners include LG Energy Solutions; the world’s largest manufacturer of Automotive Battery Cells in the world and General Motors a global company committed to delivering safer, better and more sustainable ways for people to get around.

Position Description:

The Defect Analysis (DA) Part Lead is responsible for leading the Defect Analysis function, including a team of DA engineers, to identify, analyze, and resolve product and component defects across in-line, inspection, and field-return populations. This is a hands-on technical leadership role: the Part Lead personally performs and supervises precision cell teardown analysis, renders final root-cause judgments on complex or high-stakes failures, and represents the DA function in front of internal and external stakeholders including the customer, Headquarters, and supplier engineering teams. Beyond individual analysis work, the Part Lead owns the analysis methodology, prioritization of incoming cases, technical development of team members, and the integrity of every conclusion issued by the part. Root-cause judgments from this role directly drive containment decisions, warranty determinations, and corrective actions with significant cost and customer-relationship implications; the role therefore requires deep, first-hand familiarity with lithium-ion cell internal structure and failure modes built through direct teardown experience.

Job Responsibilities:

- Lead, prioritize, and quality-review all defect analysis activities within the DA Part, including case assignment, workload balancing, and on-time closure of analysis requests.

- Personally perform and directly supervise precision dismantling and teardown analysis of defective battery cells (in-line, inspection, and field returns), including challenging teardowns requiring extended time investment to safely isolate and capture defect sites.

- Render final technical judgment on root cause for complex, ambiguous, or high-visibility failure cases, and take ownership of the accuracy and defensibility of those conclusions.

- Review and approve defect analysis reports before release; ensure findings are data-driven, reproducible, and clearly documented for multi-functional and external audiences.

- Represent the DA function in meetings with customers, global suppliers, and other battery-related stakeholders regarding component defects, material changes, field quality issues, and warranty-related analysis.

- Correlate teardown findings with manufacturing process parameters and lead cross-functional root-cause and corrective-action activities (8D, CAPA) with Production, Engineering, Development, and Quality.

- Own and continuously improve standard analysis methodologies, teardown procedures, judgment criteria, and defect classification standards for the part.

- Manage analytical lab operations, including equipment capability (SEM/EDS, CT, EA-300, electrochemical cyclers), calibration status, safety compliance, and consumables planning.

- Develop team members' teardown and analysis skills through on-the-job coaching and technical review.

Additional duties as assigned.

Qualifications and Competencies:

- Bachelor's Degree in Engineering (Chemical, Materials/New Materials, Mechanical, Electrical, or related disciplines) — required.

- Direct, hands-on experience performing cell teardown / defect analysis on lithium-ion cells — required. This is the core qualification for the role; candidates without prior hands-on teardown experience will not be able to perform the essential functions of this position.

- Master's Degree in Engineering — preferred.

- 5+ years of experience in battery cell manufacturing or quality engineering — preferred.

- In-depth knowledge of lithium-ion cell internal structure, electrode and separator materials, cell chemistry, and core manufacturing processes (electrode, assembly, formation), sufficient to independently judge root cause from physical teardown evidence — preferred.

- Working knowledge of internal cell failure modes (e.g., internal short circuit mechanisms, lithium plating, foreign material contamination, wetting/formation anomalies) and the ability to link observed defect morphology to its originating process — preferred.

- Strong understanding of defect modes originating in the cell assembly process in particular — such as tab/lead weld defects, electrode or separator stacking misalignment, separator damage, foreign material introduced during notching/stacking/welding, pouch insulation failures (e.g., Hi-pot/insulation resistance defects from pouch or tab film damage), and sealing or degassing anomalies — and how each manifests in teardown evidence — preferred.

- Experience operating material analysis equipment (SEM/EDS, CT, or equivalent) and interpreting analytical data to support root-cause conclusions — preferred.

- Experience preparing and defending technical analysis conclusions in front of customers, management, or external parties — preferred.

- Hands-on experience working directly with the customer on quality projects — such as joint defect investigations, field/warranty issue resolution, or customer-facing analysis programs — preferred.

- Experience with 8D, CAPA, and horizontal deployment of corrective actions in an automotive quality environment — preferred.

- Strong written and verbal communication skills to prepare meaningful technical reports and coordinate across functions.

- Ability to perform the essential physical functions of the role — precision manual dismantling using hand tools, extended periods of focused benchwork, and work in controlled environments such as dry rooms — with or without reasonable accommodation.

- Positive, dedicated attitude and ability to work in a team environment to drive success.

- Willingness and ability to work flexible hours or overtime occasionally to accommodate urgent defect analysis requests and external testing timelines.

Total Rewards Information:

We offer market-competitive compensation including base pay and incentive compensation opportunities based on the achievement of Company goals.  We offer employees paid time off to refresh and recharge. Our total rewards program is designed to enrich your life at work and includes the following benefits:

•    100% Employer paid Medical, Dental, and Vision

•    Generous paid holidays 

•    Tuition Assistance for continuing education

•    Vehicle Discount Program on General Motors branded vehicles

•    Communication Stipend for Personal Cell Phone

Ultium Cells LLC is an Equal Opportunity Employer:

We extend equal employment opportunities to qualified applicants and employees on an equal basis regardless of an individual's age, race, color, sex, religion, national origin, disability, sexual orientation, gender identity or expression, pregnancy status, marital status, military or veteran status, genetic disposition or any other reason protected by law.

Ultium Cells will only employ those who are legally authorized to work in the United States. This is not a position for which Visa-sponsorship will be provided. Individuals who need sponsorship for work authorization, now or in the future, are not eligible for hire for this role. 

Employee may be exposed to or working with hazardous materials and/or hazardous waste. Upon hire, employee will receive initial Environmental training over RCRA, SWPPP, SPCC, and emergency escalation. Annual refresher training will be completed every year after to fulfill the requirements of 40 CFR. Other training to be provided as required.

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