Head – Process Engineering | BESS
Department: Engineering / Manufacturing Engineering
Level: Head / AGM / DGM
Location: Chennai / Oragadam
Industry: Battery Energy Storage Systems (BESS)
Role Purpose
Lead the Process Engineering function for BESS manufacturing, covering cell-to-module, module-to-pack, LV/HV pack, rack and container integration. The role will be responsible for process design, NPI, prototype-to-mass-production industrialization, line balancing, productivity, automation, OEE, process quality, and continuous improvement.
Key Responsibilities
1. Process Engineering & Industrialization
- Lead end-to-end process engineering for BESS manufacturing lines.
- Develop and optimize manufacturing processes from prototype → pilot → SOP → mass production.
- Establish process flow, SOPs, work instructions, process parameters and control plans.
- Drive DFM/DFA and manufacturability improvements.
- Lead line layout, capacity planning, takt time and manpower optimization.
2. BESS Manufacturing Process
- Strong understanding of:
- Cell/module assembly
- Battery module and pack assembly
- Busbar and harness assembly
- BMS integration
- LV/HV pack assembly
- Rack integration
- Thermal management
- PCS/EMS integration
- BESS container integration
- Develop processes for mechanical, electrical and high-voltage assembly.
- Ensure robust processes for lithium-ion battery manufacturing and handling.
3. NPI & Prototype Development
- Lead NPI activities for new BESS products.
- Coordinate with R&D, Design, Quality, Production, SCM and Projects teams.
- Conduct process validation, pilot builds, FAI and production trials.
- Drive smooth transition from engineering prototype to commercial production.
- Identify process risks and establish mitigation plans before SOP.
4. Automation & Manufacturing Excellence
- Identify opportunities for automation, robotics, laser welding, testing and digital manufacturing.
- Drive OEE, FPY, cycle-time, throughput and productivity improvements.
- Implement Lean Manufacturing, Kaizen, Six Sigma and waste reduction initiatives.
- Optimize manpower, equipment utilization and line balancing.
5. Quality & Process Control
- Lead PFMEA, Control Plan, Process Flow, SOP and work instruction development.
- Identify critical-to-quality and critical-to-process parameters.
- Drive root-cause analysis using 8D, 5 Why, Fishbone, SPC and DOE.
- Work closely with Quality to reduce defects, rework and customer complaints.
- Ensure compliance with applicable BESS, battery and electrical safety standards.
6. Cost & Commercial Engineering
- Drive process-cost reduction through:
- Cycle-time reduction
- Manpower optimization
- Automation
- Yield improvement
- Material utilization
- Tooling optimization
- Evaluate CAPEX and OPEX requirements for new manufacturing lines.
- Support vendor evaluation and technical-commercial negotiations for process equipment and automation.
7. Team Leadership
- Build and lead the Process Engineering team.
- Define KPIs, competency requirements and development plans.
- Mentor process, manufacturing and industrial engineers.
- Establish standard engineering practices across BESS manufacturing lines.
Key KPIs
- OEE improvement
- FPY / Yield improvement
- Cycle-time reduction
- Line capacity utilization
- Process defect reduction
- NPI/SOP adherence
- Manufacturing cost reduction
- Automation percentage
- CAPEX optimization
- Productivity improvement
- Process capability / Cp & Cpk
Desired Candidate Profile
- 15–20+ years of experience in Process Engineering / Manufacturing Engineering / Industrial Engineering.
- Experience in Lithium-ion Battery, BESS, EV Battery, Automotive, Electronics or Energy Storage manufacturing.
- Strong exposure to module/pack/HV battery manufacturing and high-voltage systems preferred.
- Experience in setting up new manufacturing lines / greenfield plants will be highly desirable.
- Strong knowledge of PFMEA, DFMEA, DFM/DFA, Lean, Six Sigma, OEE, line balancing and NPI.
- Experience with automation, PLC/MES and manufacturing traceability systems preferred.
- Engineering degree in Mechanical / Electrical / Electronics / Mechatronics / Industrial Engineering.
- Strong leadership, cross-functional coordination and project-management skills
