Head – Process Engineering | BESS Department: Engineering / Manufacturing Engineering Level: Head / AGM / DGM Location: Chennai / Oragadam Industry: Battery Energy Storage Systems (BESS) Role Purpose Lead the Process Engineering function for BESS manufacturing, covering cell-to-module, module-to-pack, LV/HV pack, rack and container integration. The role will be responsible for process design, NPI, prototype-to-mass-production industrialization, line balancing, productivity, automation, OEE, process quality, and continuous improvement. Key Responsibilities 1. Process Engineering & Industrialization - Lead end-to-end process engineering for BESS manufacturing lines. - Develop and optimize manufacturing processes from prototype → pilot → SOP → mass production. - Establish process flow, SOPs, work instructions, process parameters and control plans. - Drive DFM/DFA and manufacturability improvements. - Lead line layout, capacity planning, takt time and manpower optimization. 2. BESS Manufacturing Process - Strong understanding of: - Cell/module assembly - Battery module and pack assembly - Busbar and harness assembly - BMS integration - LV/HV pack assembly - Rack integration - Thermal management - PCS/EMS integration - BESS container integration - Develop processes for mechanical, electrical and high-voltage assembly. - Ensure robust processes for lithium-ion battery manufacturing and handling. 3. NPI & Prototype Development - Lead NPI activities for current BESS products. - Coordinate with R&D;, Design, Quality, Production, SCM and Projects teams. - Conduct process validation,



pilot builds, FAI and production trials. - Drive smooth transition from engineering prototype to commercial production. - Identify process risks and establish mitigation plans before SOP. 4. Automation & Manufacturing Excellence - Identify opportunities for automation, robotics, laser welding, testing and digital manufacturing. - Drive OEE, FPY, cycle-time, throughput and productivity improvements. - Implement Lean Manufacturing, Kaizen, Six Sigma and waste reduction initiatives. - Optimize manpower, equipment utilization and line balancing. 5. Quality & Process Control - Lead PFMEA, Control Plan, Process Flow, SOP and work instruction development. - Identify critical-to-quality and critical-to-process parameters. - Drive root-cause analysis using 8D, 5 Why, Fishbone, SPC and DOE. - Work closely with Quality to reduce defects, rework and customer complaints. - Ensure compliance with applicable BESS, battery and electrical safety standards. 6. Cost & Commercial Engineering - Drive process-cost reduction through:



- Cycle-time reduction - Manpower optimization - Automation - Yield improvement - Material utilization - Tooling optimization - Evaluate CAPEX and OPEX requirements for new manufacturing lines. - Support vendor evaluation and technical-commercial negotiations for process equipment and automation. 7. Team Leadership - Build and lead the Process Engineering team. - Define KPIs, competency requirements and development plans. - Mentor process, manufacturing and industrial engineers. - Establish standard engineering practices across BESS manufacturing lines. Key KPIs - OEE improvement - FPY / Yield improvement - Cycle-time reduction - Line capacity utilization - Process defect reduction - NPI/SOP adherence - Manufacturing cost reduction - Automation percentage - CAPEX optimization - Productivity improvement - Process capability / Cp & Cpk Desired Candidate Profile - 15–20+ years of experience in Process Engineering / Manufacturing Engineering / Industrial Engineering. - Experience in Lithium-ion Battery, BESS, EV Battery, Automotive, Electronics or Energy Storage manufacturing. - Strong exposure to module/pack/HV battery manufacturing and high-voltage systems preferred. - Experience in setting up new manufacturing lines / greenfield plants will be highly desirable. - Solid knowledge of PFMEA, DFMEA, DFM/DFA, Lean, Six Sigma, OEE, line balancing and NPI. - Experience with automation, PLC/MES and manufacturing traceability systems preferred. - Engineering degree in Mechanical / Electrical / Electronics / Mechatronics / Industrial Engineering. - Strong leadership, cross-functional coordination and project-management skills

📌 Head Process Engineering (Chennai)
🏢 VSL PowerHive
📍 Chennai