Description

– PDI (Pre-Dispatch Inspection) Engineer – BESS Position: PDI Engineer – Battery Energy Storage Systems (BESS)

Department: Quality Assurance

Location: Chennai

Reports To: Manager – Quality / Head of Quality

Role Summary The PDI Engineer is responsible for conducting final inspection, testing, documentation verification, and dispatch clearance of Battery Energy Storage Systems (BESS) before shipment to customers. The role ensures every BESS container, rack, pack, and associated systems meet customer specifications, quality standards, regulatory requirements, and internal acceptance criteria prior to dispatch. The objective is to eliminate field failures, reduce warranty claims, and ensure first-time-right deliveries.

Pre-dispatch inspection verifies product quality, functionality, documentation, and customer-specific requirements before shipment.

Key Responsibilities 1.

Final Product

Inspection

- Perform comprehensive Pre-Dispatch Inspection (PDI) of complete BESS systems.
- Verify assembly quality of:
- Battery Modules
- Battery Packs
- Battery Racks
- BESS Container
- PCS integration
- EMS interface
- HVAC
- Fire Suppression System
- Auxiliary Systems

- Inspect workmanship, labeling, identification, and product appearance.

2.

Electrical

Inspection

- Verify HV/LV wiring.
- Check cable routing.
- Inspect busbar installation.
- Verify torque values.
- Conduct insulation resistance tests.
- Verify grounding continuity.
- Check polarity.
- Perform dielectric withstand tests where applicable.

3.

Functional Testing

Conduct final operational testing including:

- BMS functionality
- Cell balancing
- Rack communication
- PCS communication
- EMS communication
- SOC verification
- Charge/Discharge operation
- Alarm verification
- Emergency Stop (E-Stop)
- Smoke detection
- Fire suppression system
- HVAC operation
- Door interlocks
- HMI verification

4. Mechanical Inspection
- Verify enclosure integrity.
- Check weld quality.
- Inspect mounting hardware.
- Verify torque compliance.
- Ensure no transit damage.
- Check IP sealing.
- Verify door alignment.
- Inspect cooling duct installation.
- Ensure proper cable gland installation.

5. Documentation Verification Ensure dispatch package includes:
- FAT Report
- Test Reports
- Inspection Reports
- Customer Checklists
- Electrical Drawings
- GA Drawings
- As-built Drawings
- Operation Manual
- Maintenance Manual
- Warranty Documents
- Serial Number Traceability
- Calibration Certificates

6. Dispatch Readiness
- Approve product for shipment.
- Coordinate with Logistics.
- Verify packing quality.
- Ensure shock indicators are installed.
- Verify moisture protection.
- Ensure export packaging requirements are met.
- Confirm customer-specific packaging standards.

7. Quality Documentation
- Maintain PDI checklists.
- Record inspection observations.
- Raise NCRs.
- Generate punch lists.
- Track closure of defects.
- Maintain dispatch approval records.

8. Customer Compliance Ensure product complies with:
- Customer specifications
- Internal Quality Standards
- IEC Standards
- UL Standards
- CE Requirements
- Safety Regulations
- Contractual requirements

9. Defect Management
- Identify defects before dispatch.
- Coordinate with Production for rectification.
- Verify corrective actions.
- Re-inspect after rework.
- Approve only conforming products.

10. Continuous Improvement
- Analyze recurring dispatch defects.
- Reduce customer complaints.
- Improve First Pass Yield (FPY).
- Recommend improvements in manufacturing processes.
- Support CAPA implementation.
- Participate in quality improvement initiatives.

Qualifications
- B.E./B.Tech in Electrical, Electronics, Mechanical, Mechatronics, or Instrumentation Engineering.

Experience
- 3–8 years in:
- BESS Manufacturing
- Battery Pack Assembly
- Electrical Panel Manufacturing
- Renewable Energy
- Power Electronics
- EV Battery Manufacturing
- Industrial Electrical Systems

- Experience in PDI, FAT, or final inspection is preferred.

Technical Skills
- Battery Pack Inspection
- BMS Fundamentals
- HV Safety
- Electrical Testing
- FAT Procedures
- PDI Checklists
- Root Cause Analysis
- NCR Management
- Reading Electrical Drawings
- Torque Audits




- Continuity Testing
- Insulation Resistance Testing
- Communication Protocols (CAN, Modbus)
- Quality Documentation
- MS Office
- ERP/SAP

Standards Knowledge
- IEC 62619
- IEC 62933
- IEC 62477
- UL 9540
- UL 1973
- ISO 9001
- ISO 14001
- ISO 45001

Key Competencies
- Attention to Detail
- Problem Solving
- Quality Mindset
- Analytical Skills
- Communication Skills
- Cross-functional Coordination
- Documentation Excellence
- Decision Making
- Customer Focus
- Safety Awareness

Key Performance Indicators (KPIs)
- First Pass Dispatch Approval (%)
- PDI Defect Detection Rate
- Customer Complaints after Dispatch
- Warranty Claims
- Dispatch On-Time Clearance
- FAT Pass Rate
- Documentation Accuracy
- Rework Reduction
- Dispatch Quality Score
- CAPA Closure Effectiveness

Day-to-Day Activities
- Review daily dispatch schedule.
- Perform final inspection of completed BESS units.
- Execute electrical and functional verification tests.
- Complete PDI checklists and quality documentation.
- Coordinate with Production to resolve identified defects.
- Verify implementation of corrective actions and re-inspect repaired units.
- Approve conforming systems for dispatch and issue quality clearance.
- Support customer Factory Acceptance Tests (FAT) when required.
- Track inspection metrics and recurring quality issues.
- Participate in daily quality review and continuous improvement meetings.

Today 12:44 AM assistanant manager pdi for bess jd – Assistant Manager – Pre-Dispatch Inspection (PDI) – BESS Position: Assistant Manager – Pre-Dispatch Inspection (PDI) – Battery Energy Storage Systems (BESS)

Department: Quality Assurance

Location: Chennai / Oragadam

Reports To: Manager – Quality / Head – Quality

Role Summary The Assistant Manager – PDI is responsible for leading the Pre-Dispatch Inspection (PDI) function for Battery Energy Storage Systems (BESS), ensuring that every battery module, pack, rack, container, and integrated system meets customer specifications, internal quality standards, and applicable international regulations before shipment. The role oversees final inspection, functional testing, documentation review, and dispatch readiness while coordinating with Production, Engineering, Testing, Supply Chain, and Logistics to achieve defect-free and on-time deliveries.

Key Responsibilities 1. Lead Pre-Dispatch Inspection Activities

- Plan and manage daily PDI activities for complete BESS systems.
- Ensure timely inspection of products as per production and dispatch schedules.
- Allocate inspection activities among team members.
- Ensure compliance with approved inspection plans and quality procedures.

2. Final Product Inspection Lead final inspection of:
- Battery Cells (where applicable)
- Battery Modules
- Battery Packs (LV/HV)
- Battery Racks
- BMS Integration
- Power Conversion System (PCS)
- Energy Management System (EMS)
- HVAC System
- Fire Detection & Suppression System
- Container Integration
- Auxiliary Systems

Verify:
- Mechanical assembly quality
- Electrical installation
- Component traceability
- Workmanship
- Labeling and product identification
- Safety compliance

3. Electrical & Functional Verification Ensure completion and review of:
- Insulation Resistance (IR) Tests
- High Voltage (Hi-Pot) Tests
- Ground Continuity Tests
- Torque Verification
- Polarity Checks
- Communication Tests (CAN, Modbus, Ethernet)
- BMS Functional Verification
- PCS Functional Tests
- EMS Communication Validation
- Charge/Discharge Simulation
- SOC/SOH Verification
- Emergency Stop (E-Stop) Validation
- Alarm & Interlock Verification
- HVAC Performance Checks
- Fire Suppression System Functional Checks

4. Documentation Review Verify completeness and accuracy of:
- Factory Acceptance Test (FAT) Reports
- PDI Checklists
- Electrical Test Reports
- Calibration Certificates




- Inspection Records
- As-Built Drawings
- Operation & Maintenance Manuals
- Warranty Documents
- Packing Lists
- Customer Inspection Reports
- Product Traceability Records

5. Customer Inspection & FAT Support
- Coordinate customer and third-party inspections.
- Lead Factory Acceptance Tests (FAT).
- Address customer observations and quality concerns.
- Ensure timely closure of inspection punch points.
- Obtain customer dispatch approval.

6. Non-Conformance Management
- Raise Non-Conformance Reports (NCRs).
- Conduct root cause analysis using 5 Why, Fishbone Diagram, and 8D methodology.
- Coordinate corrective and preventive actions (CAPA).
- Verify effectiveness of corrective actions before dispatch.

7. Dispatch Readiness Ensure products are ready for shipment by verifying:
- Packaging quality
- Export compliance
- Shock and tilt indicators
- Moisture protection
- Container cleanliness
- Product labeling
- Shipping documentation
- Customer-specific dispatch requirements

8. Team Management
- Lead and mentor PDI engineers and inspectors.
- Conduct skill development and training sessions.
- Monitor team productivity and inspection quality.
- Ensure adherence to EHS and quality practices.

9. Cross-Functional Coordination Work closely with:
- Production
- Manufacturing Engineering
- Process Engineering
- Testing & Validation
- Quality Assurance
- Supply Chain
- Stores
- Logistics
- Project Management
- Service Team

to ensure seamless product release.

10.

Continuous

Improvement

- Reduce dispatch defects and customer complaints.
- Improve First Pass Yield (FPY).
- Enhance inspection efficiency through digital checklists and standardization.
- Drive Lean Manufacturing, Kaizen, and Six Sigma initiatives.
- Analyze quality trends and implement preventive actions.

Education
- B.E./B.Tech in Electrical, Electronics, Mechanical, Mechatronics, Instrumentation, or related Engineering discipline.

Experience
- 6–10 years of experience in Quality, Final Inspection, PDI, FAT, or Manufacturing Quality.
- Minimum 3 years in Battery Energy Storage Systems (BESS), EV Battery Manufacturing, Lithium-ion Battery Packs, Renewable Energy, Power Electronics, or Electrical Equipment Manufacturing.
- Experience with containerized BESS is highly preferred.

Technical Skills
- Battery Pack &

• Rack Inspection

- BMS Architecture
- PCS &

• EMS Integration

- High Voltage Safety
- Electrical Testing (IR, Hi-Pot, Ground Continuity)
- Functional Testing &

• FAT

- Reading Electrical Schematics and GA Drawings
- Quality Management Systems (QMS)
- NCR &

• CAPA Management

- Root Cause Analysis (8D, 5 Why, Fishbone)
- PFMEA &

• Control Plans

- SAP/ERP Systems
- MS Office

Knowledge of Standards
- IEC 62619
- IEC 62933
- IEC 62477
- UL 9540
- UL 1973
- ISO 9001
- ISO 14001
- ISO 45001
- Relevant customer and utility specifications

Key Competencies
- Leadership and Team Management
- Robust Analytical &

• Problem-Solving Skills

- Attention to Detail
- Decision-Making
- Customer Focus
- Effective Communication
- Cross-Functional Collaboration
- Planning &

• Organizing

- Quality Mindset
- Continuous Improvement Orientation

Key Performance Indicators (KPIs)
- On-Time PDI Completion (%)
- First Pass Dispatch Approval Rate
- Customer Acceptance Rate During FAT
- Dispatch-Related Customer Complaints
- Warranty Claims Due to Manufacturing Defects
- Number of NCRs Raised and Closed
- CAPA Closure Effectiveness
- Documentation Accuracy
- Rework Reduction
- Inspection Productivity
- First Pass Yield (FPY)
- On-Time Dispatch Performance

Day-to-Day Activities
- Review daily production and dispatch plans.
- Allocate inspection tasks to the PDI team.
- Conduct final inspections and witness functional tests.
- Review test reports and quality documentation.
- Lead customer FATs and third-party inspections.
- Coordinate defect resolution with Production and Engineering.
- Approve completed BESS units for dispatch.
- Monitor quality KPIs and prepare daily/weekly inspection reports.
- Conduct team meetings, training, and continuous improvement reviews.
- Ensure compliance with safety, quality, and regulatory requirements throughout the dispatch process.

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