Key Responsibilities and Required Skills for Battery Assembler

🎯 Role Definition

A Battery Assembler is a hands-on manufacturing technician responsible for building, testing, and inspecting battery cells and battery packs (commonly lithium-ion) to meet engineering specifications and quality standards. This role requires precise manual assembly, adherence to standard operating procedures (SOPs), ESD and cleanroom protocols, use of specialized tooling (spot welders, crimpers, ultrasonic welders), and consistent documentation of process data. Battery Assemblers work closely with quality, production engineering, and supply chain teams to ensure safe, reliable, and scalable battery manufacturing.

📈 Career Progression

Typical Career Path

Entry Point From:

Production Assembler (electronics or mechanical)
Electronics Technician / Soldering Technician
Manufacturing Operator (cleanroom/ESD environments)

Advancement To:

Senior Battery Assembler / Lead Assembler
Battery Manufacturing Technician II / Process Technician
Quality Technician (battery testing & validation)
Production Supervisor / Line Lead
Manufacturing Engineer (battery processes)

Lateral Moves:

Test Technician (formation, capacity, cycling)
Maintenance Technician (electrical/mechanical)
Materials/Inventory Specialist (kitting & supply chain support)

Core Responsibilities

Primary Functions

Assemble cells, modules, and battery packs according to engineering drawings, bills of materials (BOMs), and work instructions, ensuring each build meets dimensional and electrical specifications.
Perform precision joining operations including ultrasonic welding, spot welding, and crimping of tabs and interconnects, calibrating equipment and verifying weld quality against acceptance criteria.
Execute electrode stacking or winding operations (where applicable) with consistent spacing, alignment, and tension control to meet cell performance requirements.
Prepare and inspect components (anode, cathode, separators, current collectors) prior to assembly to detect and remove defects, contamination, or foreign material.
Operate formation and aging equipment to perform initial charge/discharge cycles, logging voltage, current, and temperature profiles and flagging anomalies to engineering and quality teams.
Conduct in-process electrical tests (open-circuit voltage, internal resistance, continuity) and mechanical checks (torque, seal integrity) and record results in electronic or paper batch records.
Follow and improve electrostatic discharge (ESD) controls and cleanroom protocols (garbing, gowning, particulate control) to protect sensitive cell components and maintain ISO cleanroom classifications.
Read and interpret engineering drawings, assembly schematics, and process control documents to ensure accurate assembly and consistency across production lots.
Calibrate, maintain, and perform basic troubleshooting on assembly fixtures, test stands, torque drivers, and weld heads; escalate complex faults to maintenance or engineering as needed.
Perform leak testing, vacuum/pressure checks, and seal inspections on cell housings and pack enclosures to ensure hermeticity and safety compliance.
Label, trace, and document lot codes, serial numbers, and manufacturing data in the MES or other traceability systems for regulatory compliance and product genealogy.
Execute final visual inspections and functional testing of completed modules and packs, including BMS connectivity checks and basic software communications validation.
Participate in incoming materials inspection and kitting—verify components against BOMs and ensure subassemblies are staged correctly for assembly operations.
Monitor process parameters (temperature, humidity, torque, weld energy) and participate in SPC / control chart activities to maintain process capability and reduce variation.
Adhere to strict safety procedures for handling hazardous or reactive battery materials, including safe storage, spill response, and proper disposal of waste and consumables.
Identify nonconforming materials or assemblies, perform containment actions, document discrepancies in NCRs, and support root cause investigations and corrective actions.
Support continuous improvement (Kaizen) initiatives by collecting process data, suggesting process optimizations, and participating in small improvement teams to increase yield and throughput.
Train and mentor new assemblers on SOPs, safety rules, ESD/cleanroom behavior, tooling use, and quality expectations to accelerate onboarding and preserve institutional knowledge.
Manage rework and repair operations following approved procedures to recover assemblies while preserving traceability and quality records.
Work cross-functionally with design, test, and process engineering to qualify new fixtures, tooling, and assembly sequences; provide practical feedback to improve manufacturability.
Maintain accurate batch records, logbooks, and electronic records in accordance with regulatory and internal quality systems to support audits and product certification.
Support production scheduling and meet daily output targets while balancing quality and safety priorities; escalate potential schedule impacts to supervisors promptly.

Secondary Functions

Assist quality and engineering teams during internal and external audits, providing documentation, process descriptions, and on-floor demonstrations of assembly activities.
Support inventory control and raw material handling, including cycle counts, FIFO/FEFO staging, labeling, and replenishment of kitted supplies.
Participate in routine preventive maintenance of bench-level tools and fixtures, performing cleaning, inspection, and minor repairs to maintain uptime.
Contribute to training material updates, visual work instructions, and SOP revisions to reflect process improvements and lessons learned.
Help investigate customer-returned units and field failures by disassembling, documenting findings, and collaborating on containment steps and corrective actions.
Maintain a clean, organized, and safety-compliant workstation, report potential hazards, and promote a culture of workplace safety and environmental responsibility.
Execute ad-hoc test cycles or sample builds to support engineering validation, new product introduction, or pilot production runs.
Collect and digitize production metrics and shop floor observations to support continuous improvement and real-time decision-making.
Provide shift coverage and cross-train across adjacent assembly operations to ensure flexible and resilient production capacity.
Support packaging and shipping preparation for completed battery modules/packs, ensuring correct labeling, documentation, and transport requirements for hazardous goods.

Required Skills & Competencies

Hard Skills (Technical)

Proficient in battery assembly processes including cell handling, tab welding (spot/ultrasonic), crimping, and pack-level assembly.
Hands-on experience with formation/aging test equipment and familiarity with charge/discharge protocols, cycle data interpretation, and basic cell characterization.
Strong understanding of ESD controls, cleanroom practices (ISO classifications) and contamination control for sensitive electronics and battery materials.
Ability to read and interpret engineering drawings, schematics, BOMs, and written work instructions with accuracy.
Skilled in using precision hand tools, torque drivers, calipers, micrometers, multimeters, and bench-level test instruments.
Experience with leak detection, pressure/vacuum testing, and mechanical sealing techniques used in cell and pack assembly.
Knowledge of battery safety practices (thermal management basics, safe handling of electrodes and electrolytes, hazard communication).
Familiarity with quality systems and record keeping (MES, ERP, batch records, NCRs, CAPA) and traceability best practices.
Basic understanding of Battery Management Systems (BMS) interfaces, wiring, and communication checks (CAN, SMBus, UART).
Ability to perform first-line troubleshooting and basic maintenance on spot welders, ultrasound welders, torque tools, and test fixtures.
Experience with statistical process control (SPC), basic metrology, and continuous improvement tools (5S, Kaizen, root cause analysis).
Certification-friendly skills: IPC soldering standards, J-STD-001 awareness, or other electronics assembly certifications considered a plus.

Soft Skills

Exceptional attention to detail and a strong quality-first mindset to consistently detect defects and prevent rework.
Excellent manual dexterity and hand-eye coordination for fine-pitch assembly and delicate operations.
Strong communication skills to clearly report test results, defects, and process observations to supervisors and engineering.
Team-oriented with the ability to work cross-functionally and support shift-based production dynamics.
Problem-solving aptitude with willingness to escalate, document, and contribute to corrective action plans.
Time management and organization skills to meet production targets while maintaining compliance with safety and quality standards.
Adaptability and learning agility to adopt new processes, equipment, and product variants quickly.
Reliability and ownership—punctual attendance, consistent performance, and commitment to safety protocols.
Coaching ability to train new team members and share best practices on the shop floor.
Continuous improvement mindset, proactively identifying process inefficiencies and proposing solutions.

Education & Experience

Educational Background

Minimum Education:

High School Diploma or GED required.

Preferred Education:

Associate degree, technical diploma, or certificate in Electronics, Mechatronics, Industrial Technology, or Manufacturing Technology.
Specialized training in battery technologies, electrochemical safety, or welding/assembly certifications is a plus.

Relevant Fields of Study:

Electrical/Electronics Technology
Mechanical/Manufacturing Technology
Materials Science or Chemical Technology (battery-focused courses)
Mechatronics / Automation Technology

Experience Requirements

Typical Experience Range:

0–3 years for entry-level assembler roles; 2–5 years for mid-level battery assembler positions.

Preferred:

1–3 years experience with lithium-ion battery cell/pack assembly, or 2+ years in electronics assembly with battery-related exposure.
Prior experience in an ISO-classified cleanroom, ESD-controlled environment, or regulated manufacturing setting preferred.
Demonstrated experience with welding/crimping equipment, formation/test stands, and electronic test procedures favored.