Description
Job Summary

The Head of Process Engineering will lead the development, optimization, and industrialization of manufacturing processes for Battery Energy Storage System (BESS) products. The role is responsible for establishing robust, scalable, and cost-effective manufacturing processes from prototype to mass production while ensuring world-class quality, safety, and productivity.

The incumbent will collaborate with Product Engineering, Manufacturing, Quality, Supply Chain, Automation, Maintenance, and R&D; teams to drive operational excellence and continuous improvement.

Key Responsibilities 1. Process Development & Industrialization

- Develop and standardize manufacturing processes for BESS products, including:
- Battery Module Assembly
- Battery Pack Assembly
- HV/LV Harness Assembly
- Rack Assembly
- BESS Container Integration

- Lead Recent Product Introduction (NPI) from prototype through pilot production to mass manufacturing.
- Define manufacturing process flow, cycle time, line balancing, takt time, and capacity planning.
- Drive Design for Manufacturing (DFM) and Design for Assembly (DFA) initiatives.

2. Manufacturing Engineering
- Establish manufacturing standards, SOPs, work instructions, and process documentation.
- Develop manufacturing layouts, workstation design, and material flow.
- Select and commission production equipment, tooling, fixtures, and automation systems.
- Lead PFMEA, Process Validation (IQ/OQ/PQ), Process Capability (Cp/Cpk), and Control Plan development.
- Improve manufacturing efficiency through Lean Manufacturing and Six Sigma methodologies.

3. Automation & Digital Manufacturing
- Drive automation initiatives for:
- Cell handling
- Laser welding
- Busbar assembly
- Screw fastening
- Adhesive dispensing
- Vision inspection

- Work with PLC, MES, SCADA, Barcode, and Traceability systems.
- Implement Industry 4.0 practices and digital manufacturing initiatives.

4. Continuous Improvement
- Improve:
- OEE
- First Pass Yield (FPY)
- Throughput
- Productivity




- Cycle Time
- Cost per Unit

- Conduct Root Cause Analysis using:

- 8D
- Fishbone
- Why-Why Analysis
- FMEA

- Eliminate manufacturing bottlenecks.

5. Quality & Compliance
- Ensure compliance with:
- ISO 9001
- ISO 14001
- ISO 45001
- IEC
- UL
- CE Standards

- Work closely with Quality team to reduce defects and improve process capability.
- Support APQP, PPAP, and customer audits.

6. Cross Functional Collaboration
- Coordinate with:
- Product Design
- R&D;
- Quality
- Production
- Supply Chain
- Maintenance
- Automation Team

- Ensure smooth transfer of engineering designs into manufacturing.

7. Team Leadership
- Build and mentor a high-performing Process Engineering team.
- Define KPIs and development plans for engineers.
- Drive technical capability development across manufacturing.

8. Cost Optimization
- Reduce manufacturing cost through:
- Process optimization
- Automation
- Material utilization
- Cycle time reduction
- Waste elimination

- Support annual cost reduction initiatives.

Required Technical Skills
- Strong understanding of:
- Lithium-ion Battery Manufacturing
- Battery Module Assembly
- Battery Pack Assembly
- BESS Manufacturing
- Container Integration

- Expertise in:

- PFMEA
- DFMEA
- APQP
- PPAP
- Lean Manufacturing
- Six Sigma
- SPC
- Control Plans
- Line Balancing
- Time Study
- Work Measurement

- Experience with:

- PLC
- MES
- SCADA
- Robotics
- Laser Welding
- Automated Assembly Systems

- Knowledge of battery safety standards and manufacturing best practices.

Educational Qualification
- Bachelor's Degree in Mechanical, Electrical, Mechatronics, Industrial Engineering, or Manufacturing Engineering.
- Master's Degree preferred.
- Lean Six Sigma Green Belt/Black Belt certification is an added advantage.

Experience
- 15–20 years of experience in Manufacturing/Process Engineering.
- Minimum 8 years in leadership roles.
- Hands-on experience in:
- Battery Manufacturing
- Energy Storage Systems (ESS/BESS)
- EV Battery Manufacturing
- Electronics Manufacturing
- High-volume automated assembly

📌 Assistant General Manager - Process Engineer (India)
🏢 Vikram Solar
📍 India