Role Mandate
Suzlon is building a BESS business where the factory must behave like a product operation, not a project workshop
The BESS Manufacturing Lead will stand up, stabilize, and continuously improve Suzlon's BESS pack assembly and containerization operations with takt-based planning, quality gates, full traceability, and strong EHS governance—so the BU can deliver a standardized, certifiable, warranty-ready product at competitive cost.
This role is a critical early hire and will own safety readiness, right-first-time quality, and predictable delivery.
Key Responsibilities
- Brownfield integration & commissioning
- Lead retrofit and integration of new pack/container lines within an existing plant environment (layout, utilities, material flow, EHS zoning, storage and handling for Li-ion)
- Own plant infrastructure readiness for Li-ion operations: HV safety controls, zoning, emergency response preparedness, controlled storage, training & certification.
- Oversee FAT/SAT, installation, commissioning and performance acceptance of imported equipment with clear acceptance criteria and vendor accountability
- Deliver structured ramp-up to stable 1.5 GWh capacity, with defined ramp gates (pilot builds → rate builds → steady state)
2) Industrialization & process stabilization
- Run pack assembly as a product operation: takt-based planning, standard work, quality gates, and traceability as non-negotiables
- Establish the industrialization bridge with CTO: DFM/DFA, process windows, CTQs, line balancing, and manufacturability-driven updates—while respecting CTO's design/change authority
- Create a robust process engineering bench (lean but high impact) focused on yield/ramp-up and factory learning—not only running shifts (peer benchmark insight)
3. Manufacturing Operations & Multi-Shift Leadership
- Convert annual capacity targets into monthly/weekly/daily production plans with clear WIP controls and dispatch readiness gates.
- Implement scalable 2/3 shift operations with tiered daily management cadence (SQDC boards, tier reviews, escalation governance).
- Lead plant functions: Production, Industrial/Process Engineering, Quality, Maintenance/Utilities, Warehouse/Stores, and EHS
3. Quality, Compliance & EHS Governance
- Implement a manufacturing QMS suitable for Li‑ion operations: PFMEA, control plans, layered process audits, CAPA, deviation management, containment and MRB
- Build end-to-end traceability (cell → module → pack → container; test data retention; audit-ready documentation)
- Institutionalize high-voltage safety: HV work permits, LOTO, interlocks validation, arc‑flash practices, thermal incident response drills, safe storage and handling
- Ensure compliance readiness for applicable battery/BESS expectations (e.g., IEC/UL system safety norms as applicable; UN 38.3 transport readiness; Indian statutory requirements)
- Drive supplier quality management for external components (import + domestic): incoming quality gates, PPAP/qualification, supplier audits, corrective actions
4. Container Integration & System-Level Readiness
- Oversee mechanical, electrical and thermal integration into containerized systems; ensure robust grounding, interlocks, insulation/HV safety controls and safe routing
- Own end-of-line testing, validation evidence and dispatch documentation (traceability dossier + test certificates + FAT readiness packs)
- Interface with CTO/Engineering and Projects/EPC for controlled change management and design/process improvements (no uncontrolled deviations)
5. Planning, logistics & the Hybrid interface
- Own factory S&OP handshake: demand signal from BU/Wind BD, material readiness with Procurement, and dispatch alignment with EPC site schedules
- Define SLAs and escalation paths with shared Wind functions (Procurement/EPC/OMS) to ensure resourcing and decision speed
6. Cost, Productivity & Continuous Improvement
- Own conversion cost roadmap: labor productivity, yield/scrap, rework reduction, cycle time and line balance improvements
- Drive OEE improvements through TPM discipline: preventive maintenance adherence, spares strategy, uptime governance for imported equipment
Success Measures
Dimension - Measures
Capacity & delivery - Ramp milestones to stable 1.5 GWh; throughput (MWh/month vs plan); OTIF dispatch; schedule adherence.
Operational excellence - OEE; First Pass Yield (FPY); cycle time reduction; labor productivity; stable takt achievement.
Quality & traceability - DPPM / defect rate; containment effectiveness; audit NCs and closure speed; full genealogy + test-data availability.
Safety - TRIR / LTIFR; HV safety compliance; near-miss closure discipline; emergency response drill readiness.
Cost & efficiency - Conversion cost per kWh; scrap & rework %; inventory turns; PM adherence and equipment uptime.
Candidate Profile
Experience & Background
- 8-12+ years in manufacturing leadership across battery pack/EV systems/power electronics/heavy electrical assembly/industrial product operations (hands-on plant leadership preferred)
- Demonstrated experience in setting up and stabilizing a new manufacturing line (industrialization + ramp-up + yield stabilization).
- Track record operating with rigorous quality systems, traceability, and safety governance in high-risk environments.
- Demonstrated ownership of plant-level KPIs (safety, quality, delivery, cost)
Domain Expertise (Must-Have)
- Strong understanding of pack/module assembly processes, quality gates, and typical failure modes (electrical isolation, connection integrity, thermal issues, workmanship variation)
- Familiarity with containerized BESS integration (mechanical fitment, electrical integration, system-level testing)
- Working knowledge of battery safety and regulatory frameworks (UL/IEC, UN 38.3, Indian compliance environment)
- Exposure to MES, traceability systems, and automated assembly environments
- Experience building plant cadence (daily management), continuous improvement, and problem-solving culture
- Working knowledge of Lean manufacturing and OEE-driven plant management
Education
- B.E./B.Tech in Mechanical / Electrical / Electronics / Industrial Engineering
- Postgraduate qualification in Operations/Manufacturing (MBA or equivalent) preferred
