ROLE MANDATE

Suzlon is building a BESS business in which the factory must behave like a product operation, not a project workshop. The Lead – Production stands up, stabilizes and continuously improves Suzlon's BESS pack assembly and containerization operations — with takt-based planning, quality gates, full traceability and strong EHS governance — so the BU can ship a standardized, certifiable, warranty-ready product at competitive cost.
This is a foundational hire and a build role rather than a caretaker role. It owns safety readiness, right-first-time quality and predictable delivery, taking the plant from brownfield integration and commissioning through pilot builds, rate builds and stable multi-shift operation at ~3 GWh. The role suits a strong, hands-on manager ready to step up — depth of ownership and industrialization instinct matter more than years served.

KEY RESPONSIBILITIES

Brownfield Integration, Commissioning & Ramp-Up
Lead retrofit and integration of new pack and container lines within an existing plant workplace — layout, utilities, material flow, EHS zoning, and controlled storage and handling for Li-ion
Own plant infrastructure readiness for Li-ion operations: HV safety controls, zoning, controlled storage, emergency-response preparedness, and operator training and certification
Oversee FAT / SAT, installation, commissioning and performance acceptance of imported equipment with clear acceptance criteria and enforceable vendor accountability
Deliver a structured ramp to stable ~3 GWh capacity through defined ramp gates — pilot builds, rate builds, steady state — with exit criteria at each gate

Industrialization & Process Stabilization
Run pack assembly as a product operation — takt-based planning, standard work, quality gates and traceability as non-negotiables
Own the industrialization bridge with Head – Technical / Product Engineering: DFM / DFA, process windows, CTQs, line balancing and manufacturability-driven design feedback — while respecting central design and change authority
Build a lean but high-impact process-engineering bench focused on yield, ramp-up and factory learning, not only on running shifts
Establish standard work instructions, operator certification matrices and process-capability baselines for every critical station

Manufacturing Operations & Multi-Shift Leadership
Convert annual capacity targets into monthly, weekly and daily production plans with clear WIP controls and dispatch-readiness gates
Implement scalable 2 / 3-shift operations with a tiered daily management cadence — SQDC boards, tier reviews and disciplined escalation governance
Lead plant functions: Production, Industrial / Process Engineering, Maintenance & Utilities, Warehouse / Stores, and plant-level EHS execution
Recruit,



train and deploy the shop-floor and supervisory team from scratch, building supervisory bench strength ahead of the ramp

Quality, Compliance & EHS Execution
Deploy the manufacturing QMS on the shop floor with Lead – QHSE — PFMEA, control plans, layered process audits, CAPA, deviation management, containment and MRB
Operate end-to-end traceability (cell → module → pack → container) with test-data retention and audit-ready documentation
Institutionalize high-voltage safety — HV work permits, LOTO, interlock validation, arc-flash practice, thermal-incident response drills, and safe storage and handling
Maintain compliance readiness for applicable battery and BESS norms (IEC / UL system safety as applicable, UN 38.3 transport readiness, Indian statutory requirements)
Support incoming-quality gates, PPAP / qualification and supplier audits for imported and domestic components alongside Procurement and QHSE

Container Integration & Dispatch Readiness
Oversee mechanical, electrical and thermal integration into containerized systems — grounding, interlocks, insulation and HV safety controls, and safe cable routing
Own end-of-line testing, validation evidence and the dispatch documentation pack — traceability dossier, test certificates and FAT-readiness packs per shipment
Enforce dispatch discipline: no release without complete test records and quality clearance
Interface with Product Engineering and Projects / EPC for controlled change management, with zero uncontrolled deviations on the line

Planning, Logistics & Cost
Own the factory S&OP; handshake — demand signal from the BU and 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 protect resourcing and decision speed
Own the conversion-cost roadmap — labour productivity, yield and scrap, rework reduction, cycle time and line-balance improvement
Drive OEE through TPM discipline: preventive-maintenance adherence, spares strategy and uptime governance for imported equipment

Field Feedback & Continuous Improvement
Run the closed-loop OMS → Manufacturing → Product Engineering learning loop with structured RCA and verified corrective actions to cut warranty exposure
Build a problem-solving and continuous-improvement culture on the floor, with visible kaizen and daily-management discipline




Maintain a defect-and-resolution knowledge base so recurring build issues drive permanent process and design fixes

SUCCESS MEASURES

Capacity & delivery: Ramp milestones to stable ~3 GWh achieved; throughput (MWh/month vs plan), OTIF dispatch and schedule adherence on target
Operational excellence: OEE, First Pass Yield, cycle-time reduction, labour productivity and stable takt attainment
Quality & traceability: DPPM / defect rate on target; containment effectiveness; audit NCs closed on time; 100% genealogy and test-data availability
Safety: TRIR / LTIFR within limits; HV safety compliance; near-miss closure discipline; emergency-response drill readiness
Cost & efficiency: Conversion cost per kWh, scrap and rework %, inventory turns, PM adherence and equipment uptime
Team & cadence: Plant team recruited and certified per plan; daily management system running with disciplined escalation

CANDIDATE PROFILE

Experience & Background
5–10 years in manufacturing across battery pack / EV systems, power electronics, heavy electrical assembly or industrial product operations, with hands-on shop-floor ownership
Exposure to setting up or stabilizing a new manufacturing line — industrialization, ramp-up and yield stabilization — even if as a core team member rather than the overall plant head
Track record of operating within rigorous quality, traceability and safety systems in a high-risk manufacturing environment
Demonstrated ownership of line- or plant-level KPIs across safety, quality, delivery and cost
Experience leading shop-floor teams and running a shift or line cadence; readiness to scale into multi-shift plant leadership

Domain Expertise
Strong understanding of pack / module assembly processes, quality gates and typical failure modes — electrical isolation, connection integrity, thermal issues and workmanship variation
Familiarity with containerized BESS integration: mechanical fitment, electrical integration and 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 semi-automated or automated assembly environments
Working command of Lean manufacturing, OEE-driven plant management, TPM and structured problem solving (8D / 5-Why)

Attributes
Builder's mindset — equally comfortable writing the first SOP and standing on the line during a pilot build
Bias for daily discipline and escalation clarity over ad-hoc firefighting
Willingness to stop the line on a safety or quality concern, and the credibility to make it stick

Education
B.E. / B.Tech in Mechanical, Electrical, Electronics or Industrial Engineering
Postgraduate qualification in Operations / Manufacturing (MBA or equivalent) preferred; Lean / Six Sigma certification an advantage

📌 Lead – Production (BESS) (Shivamogga)
🏢 Suzlon Group
📍 Shivamogga