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 new 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 recent 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.
Strong 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