Job Description

Head – Process Engineering | BESS

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Department: Engineering / Manufacturing Engineering

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Level: Head / AGM / DGM

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Location: Chennai / Oragadam

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Industry: Battery Energy Storage Systems (BESS)

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Role Purpose

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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.

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Key Responsibilities

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1. Process Engineering & Industrialization

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- Lead end-to-end process engineering for BESS manufacturing lines.
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- Develop and optimize manufacturing processes from prototype → pilot → SOP → mass production.
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- Establish process flow, SOPs, work instructions, process parameters and control plans.
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- Drive DFM/DFA and manufacturability improvements.
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- Lead line layout, capacity planning, takt time and manpower optimization.
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2. BESS Manufacturing Process

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- Solid understanding of:
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- Cell/module assembly
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- Battery module and pack assembly
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- Busbar and harness assembly
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- BMS integration
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- LV/HV pack assembly
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- Rack integration
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- Thermal management
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- PCS/EMS integration
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- BESS container integration
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- Develop processes for mechanical, electrical and high-voltage assembly.
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- Ensure robust processes for lithium-ion battery manufacturing and handling.
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3. NPI & Prototype Development

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- Lead NPI activities for new BESS products.
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- Coordinate with R&D;, Design, Quality, Production, SCM and Projects teams.
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- Conduct process validation, pilot builds, FAI and production trials.
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- Drive smooth transition from engineering prototype to commercial production.
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- Identify process risks and establish mitigation plans before SOP.
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4. Automation & Manufacturing Excellence

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- Identify opportunities for automation, robotics, laser welding, testing and digital manufacturing.
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- Drive OEE, FPY, cycle-time, throughput and productivity improvements.
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- Implement Lean Manufacturing, Kaizen, Six Sigma and waste reduction initiatives.
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- Optimize manpower, equipment utilization and line balancing.
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5. Quality & Process Control

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- Lead PFMEA, Control Plan, Process Flow, SOP and work instruction development.
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- Identify critical-to-quality and critical-to-process parameters.
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- Drive root-cause analysis using 8D, 5 Why, Fishbone, SPC and DOE.
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- Work closely with Quality to reduce defects, rework and customer complaints.
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- Ensure compliance with applicable BESS, battery and electrical safety standards.
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6. Cost & Commercial Engineering

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- Drive process-cost reduction through:
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- Cycle-time reduction
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- Manpower optimization
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- Automation
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- Yield improvement
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- Material utilization
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- Tooling optimization
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- Evaluate CAPEX and OPEX requirements for new manufacturing lines.
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- Support vendor evaluation and technical-commercial negotiations for process equipment and automation.
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7. Team Leadership

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- Build and lead the Process Engineering team.
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- Define KPIs, competency requirements and development plans.
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- Mentor process, manufacturing and industrial engineers.
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- Establish standard engineering practices across BESS manufacturing lines.
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Key KPIs

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- OEE improvement
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- FPY / Yield improvement
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- Cycle-time reduction
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- Line capacity utilization
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- Process defect reduction
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- NPI/SOP adherence
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- Manufacturing cost reduction
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- Automation percentage
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- CAPEX optimization
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- Productivity improvement
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- Process capability / Cp & Cpk
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Desired Candidate Profile

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- 15–20+ years of experience in Process Engineering / Manufacturing Engineering / Industrial Engineering.
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- Experience in Lithium-ion Battery, BESS, EV Battery, Automotive, Electronics or Energy Storage manufacturing.
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- Strong exposure to module/pack/HV battery manufacturing and high-voltage systems preferred.
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- Experience in setting up new manufacturing lines / greenfield plants will be highly desirable.
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- Strong knowledge of PFMEA, DFMEA, DFM/DFA, Lean, Six Sigma, OEE, line balancing and NPI.
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- Experience with automation, PLC/MES and manufacturing traceability systems preferred.
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- Engineering degree in Mechanical / Electrical / Electronics / Mechatronics / Industrial Engineering.
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- Strong leadership, cross-functional coordination and project-management skills
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📌 Head Process Engineering (Tamil Nadu)
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