Job Description – Proto/Pilot Senior Manager (Mechanical & Electrical) – BESS Role Summary
The Proto/Pilot Senior Manager – Mechanical & Electrical (BESS) will lead prototype development, pilot production, mechanical and electrical integration, validation support, and manufacturing readiness for Battery Energy Storage System (BESS) products at a 5 GWh / 6.25 GWh manufacturing facility .
The role will act as a critical bridge between Engineering, Validation, Quality, Supply Chain, and Manufacturing to ensure successful transition from prototype development to pilot production and scalable mass manufacturing.
Key Job Responsibilities
Prototype & Pilot Build Leadership
Lead end-to-end prototype and pilot build activities for BESS products.
Manage engineering builds, design validation builds, pre-production builds, and pilot production builds.
Develop and execute prototype build plans, schedules, resource requirements, and milestones.
Drive rapid problem-solving and design iterations during prototype and pilot stages.
Ensure prototype builds are completed within defined timelines, quality, safety, and cost targets.
Lead teams of engineers, technicians, and manufacturing personnel involved in prototype and pilot builds.
Mechanical Prototype & System Integration
Lead mechanical integration of battery modules, packs, racks, enclosures, and containerized BESS systems.
Oversee assembly of structural frames, battery housings, cooling systems, mechanical interfaces, and related components.
Identify and resolve mechanical fitment, tolerance, interference, fastening, sealing, and structural issues.
Ensure proper mechanical integration across the complete BESS architecture.
Support thermal and cooling system integration, including interfaces between mechanical and thermal components.
Drive Design for Manufacturability (DFM) and Design for Assembly (DFA) improvements.
Work with mechanical design teams to incorporate prototype and pilot build learnings into future product revisions.
Support tooling, fixture, jig, and assembly process development for mechanical manufacturing.
Electrical Prototype & System Integration
Lead electrical prototype and pilot builds for battery modules, packs, racks, and complete BESS systems.
Oversee integration of high-voltage and low-voltage electrical systems.
Manage assembly and integration of busbars, cables, connectors, contactors, fuses, relays, sensors, and wiring harnesses.
Ensure proper electrical integration from Cell → Module → Pack → Rack → System → Container .
Coordinate BMS, communication, control, auxiliary power, grounding, and bonding interfaces.
Support integration with power electronics and external system interfaces.
Identify and resolve electrical interconnect, wiring, insulation, grounding, communication, and BMS-related issues.
Ensure compliance with electrical safety and HV assembly requirements.
Support development of electrical work instructions, assembly standards, inspection criteria, and testing procedures.
Pilot Production Management
Lead pilot-scale manufacturing activities and ensure pilot line readiness.
Develop and optimize assembly sequences and production processes.




Support pilot line setup, station design, material flow, and operator readiness.
Develop standard work instructions and operating procedures.
Drive cycle time reduction and throughput improvement.
Support line balancing and manpower optimization.
Improve first-pass yield and reduce scrap, rework, and process variation.
Identify manufacturing bottlenecks and implement corrective actions.
Ensure pilot processes are secure and repeatable before mass production transfer.
Support production ramp-up for the 5 GWh / 6.25 GWh BESS manufacturing facility.
Issue Resolution & Root Cause Analysis
Lead troubleshooting of prototype, pilot, mechanical, electrical, thermal, and manufacturing issues.
Investigate failures related to mechanical fitment, electrical connections, thermal performance, assembly quality, and process variation.
Conduct structured root cause analysis using tools such as:
5 Why Analysis
Fishbone Diagram
8D Problem Solving
FMEA
Drive corrective and preventive actions with Engineering, Quality, and Manufacturing teams.
Track critical issues until permanent resolution and closure.
Develop lessons learned from prototype and pilot builds.
Validation & Design Improvement
Work closely with validation and reliability teams during prototype and pilot testing.
Support functional, performance, safety, and reliability validation.
Coordinate mechanical, electrical, thermal, and system-level validation activities.
Support electrical safety testing, insulation resistance, continuity, grounding, and BMS functionality testing.
Support mechanical durability, vibration, structural, and thermal performance assessments.
Analyze validation failures and provide manufacturing and engineering feedback.
Ensure prototype learnings are incorporated into product design improvements.
Support engineering changes and product design releases.
Manufacturing Process Development
Collaborate with Manufacturing Engineering to develop scalable assembly processes.
Support development of tooling, fixtures, jigs, and error-proofing solutions.
Establish process controls and quality checkpoints.
Develop manufacturing work instructions and standard operating procedures.
Improve assembly ergonomics, material presentation, and workstation efficiency.
Support automation and semi-automation opportunities where applicable.
Ensure prototype and pilot processes are suitable for high-volume manufacturing.
Drive improvements in yield, cycle time, productivity, and manufacturing efficiency.
Cross-Functional Coordination
Work closely with Mechanical Design Engineering.
Coordinate with Electrical and HV/LV Engineering teams.
Partner with BMS and Controls Engineering teams.
Collaborate with Thermal Management Engineering.
Interface with Testing,



Validation, Quality, and Reliability teams.
Coordinate with Manufacturing Engineering and Operations.
Work with Supply Chain and Sourcing for prototype and pilot material availability.
Support supplier issue resolution and component quality improvement.
Participate in cross-functional design reviews and manufacturing readiness reviews.
Team & Program Management
Lead and mentor prototype and pilot engineers, technicians, and build teams.
Manage multiple prototype and pilot programs simultaneously.
Develop build schedules and resource plans.
Track program milestones, deliverables, and technical risks.
Ensure effective communication between engineering and manufacturing functions.
Escalate critical program, technical, quality, and manufacturing risks.
Drive a strong culture of safety, quality, accountability, and continuous improvement.
Required Qualifications
Education
Bachelor's or Master's degree in:
Mechanical Engineering
Electrical Engineering
Electronics Engineering
Mechatronics Engineering
Manufacturing Engineering
Energy Systems
Related Engineering Discipline
Experience
8–15+ years of relevant experience in BESS, lithium-ion batteries, EV, automotive, power electronics, renewable energy, or advanced manufacturing.
Strong experience in prototype and pilot build management.
Experience in battery pack, battery rack, or complete BESS system integration.
Experience in mechanical and/or electrical manufacturing processes.
Experience in transitioning products from prototype to pilot and mass production.
Experience with large-format lithium-ion battery systems is highly preferred.
Experience in LFP battery systems will be an added advantage.
Mandatory Technical Skills
Prototype and pilot manufacturing processes.
BESS and battery pack system integration.
Mechanical and electrical assembly fundamentals.
HV and LV system understanding.
Manufacturing process development.
Root cause and failure analysis.
Design for Manufacturability (DFM).
Design for Assembly (DFA).
FMEA and structured problem-solving.
Tooling and fixture development.
Work instruction and SOP development.
Pilot line setup and process stabilization.
Preferred Skills
LFP-based BESS systems.
BMS integration and communication systems.
Thermal management and cooling systems.
High-voltage electrical safety.
Power electronics and PCS interface understanding.
Process optimization and line balancing.
Reliability and validation experience.
Automated or semi-automated manufacturing.
High-volume battery manufacturing and production ramp-up.
Key Performance Indicators (KPIs)
Prototype build cycle time.
Prototype and pilot first-pass yield.
Pilot production yield and throughput.
Scrap and rework reduction.
Issue resolution turnaround time.
Design iteration efficiency.
Assembly cycle time improvement.
Process stability and repeatability.
Manufacturing readiness for mass production.
Successful pilot-to-production transfer.
Achievement of 5 GWh / 6.25 GWh production ramp-up targets.
Product robustness, quality, and manufacturability.

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