Manager – Manufacturing Engineering (BESS Container)

1. Position Details

Position: Manager – Manufacturing Engineering

Business: Battery Energy Storage System (BESS)

Product: BESS Container / Energy Storage System

Department: Manufacturing Engineering / Operations

Reporting To: AGM / Head – Manufacturing Engineering

Location: Plant / Manufacturing Facility

2. Job Purpose

The Manager – Manufacturing Engineering will be responsible for developing, industrializing, and continuously improving manufacturing processes for BESS container assembly and integration. The role will ensure that manufacturing processes are safe, efficient, scalable, cost-effective, and capable of consistently meeting defined quality, productivity, delivery, and cost targets.

The position will work closely with Design, NPD, Production, Quality, Supply Chain, EHS, Maintenance, and Project teams to ensure smooth transition of BESS products from design to mass production.

3. Key Responsibilities

A. Manufacturing Process Engineering

- Develop and establish end-to-end manufacturing processes for BESS container assembly.
- Prepare process flow diagrams, process layouts, SOPs, work instructions, and process control plans.
- Define assembly sequence, manpower requirements, cycle time, takt time, line balancing, and workstation design.
- Develop manufacturing processes for:
- Container structure and enclosure assembly
- Battery rack/module installation
- PCS integration
- HVAC installation
- Fire detection and suppression systems
- Electrical panels and cabling
- Busbar and power-cable installation
- BMS/EMS integration
- Auxiliary systems
- Final testing and commissioning

- Ensure manufacturing processes comply with approved engineering drawings and specifications.

B.

New Product

Introduction (NPI/NPD)

- Lead manufacturing engineering activities for new BESS container models.
- Review product designs from a Design for Manufacturing & Assembly (DFMA) perspective.
- Participate in design reviews, manufacturability reviews, and prototype builds.
- Identify potential manufacturing risks before product launch.
- Develop prototype-to-production transition plans.
- Establish processes and documentation for pilot and mass production.

C. Production Engineering & Productivity

- Analyze production processes and identify bottlenecks, process losses, and productivity improvement opportunities.
- Establish and monitor standard cycle times and takt times.
- Optimize manpower and workstation allocation.
- Drive line balancing and capacity improvement initiatives.
- Implement Lean Manufacturing, Kaizen, 5S, VSM, Poka-Yoke and continuous improvement practices.
- Reduce assembly time, rework, material movement, and manufacturing costs.

D. Tooling, Fixtures & Equipment

- Define requirements for manufacturing tools, fixtures, jigs, lifting equipment, test equipment, and special-purpose machines.
- Develop specifications for new manufacturing equipment.
- Coordinate with vendors for design, development, trials, installation, and commissioning.




- Ensure fixtures and tools are ergonomically designed and suitable for BESS container production.
- Establish preventive maintenance requirements for manufacturing equipment in coordination with Maintenance.

E.

Process

Quality & Compliance

- Work with Quality Engineering to establish robust process controls.
- Develop and maintain:
- PFMEA
- Control Plan
- SOP/WI
- Process flow
- Inspection standards
- Check sheets
- Error-proofing mechanisms

- Conduct root-cause analysis for process-related defects using 5 Why, Fishbone, 8D and other problem-solving techniques.
- Drive reduction in rejection, rework, defects, and customer complaints arising from manufacturing processes.

F. BESS Electrical & Mechanical Integration

- Ensure proper manufacturing processes for installation and integration of:
- Battery modules/racks
- HV/LV electrical systems
- Busbars
- DC cables
- AC cables
- PCS
- BMS
- EMS
- HVAC
- Fire detection/suppression systems
- Earthing and bonding systems
- Communication systems

- Ensure appropriate controls for electrical isolation, torqueing, insulation, cable routing, connector assembly, and labeling.
- Coordinate with Engineering for resolution of assembly and manufacturability issues.

G.

Capacity

Planning & Industrial Engineering

- Conduct capacity studies based on customer/project requirements.
- Calculate manpower, equipment, space, and production capacity requirements.
- Develop manufacturing layouts for BESS container production.
- Prepare Man-Machine-Material (3M) analysis and capacity planning.
- Support budgeting and CAPEX proposals for manufacturing expansion.

H. EHS & Safety

- Ensure manufacturing processes comply with applicable EHS requirements.
- Implement safe handling and installation practices for battery systems and electrical equipment.
- Conduct process risk assessments and ensure appropriate safety controls.
- Ensure proper handling, storage, lifting, transportation, and installation of battery modules and electrical components.
- Coordinate with EHS team for emergency preparedness and fire-safety requirements.

I. Cross-Functional Coordination

- Work closely with:
- Product Design
- BMS/EMS Engineering
- Electrical Engineering
- Mechanical Engineering
- Production
- Quality
- SCM/Purchase
- NPD
- Maintenance
- EHS
- Project Management

- Resolve production and engineering issues within defined timelines.
- Support supplier development for manufacturing-related components, tools, fixtures, and equipment.

J. Documentation & MIS

- Maintain manufacturing engineering documentation and change records.
- Control engineering changes and ensure timely implementation on the shop floor.
- Prepare reports on:
- Productivity
- Capacity utilization
- Process efficiency
- Rejection/rework
- Manufacturing cost
- Line performance




- Improvement projects

- Present manufacturing performance and improvement initiatives to management.

4. Key Performance Indicators (KPIs)

- Production capacity achievement
- Manufacturing cycle-time reduction

- Line productivity and efficiency
- OEE / equipment utilization
- First Pass Yield (FPY)
- Reduction in rejection and rework
- Manufacturing cost reduction
- New product launch readiness
- On-time completion of NPI activities
- Manpower productivity
- Process improvement / Kaizen implementation
- Safety compliance
- Customer and internal quality performance

5. Educational Qualification

- Bachelor's Degree in Mechanical / Production / Industrial / Electrical Engineering.
- Diploma with strong relevant experience may also be considered.
- Additional qualification in Industrial Engineering, Manufacturing Engineering, Lean Manufacturing, or Project Management will be an advantage.

6. Experience

- 8–12 years of relevant experience in Manufacturing Engineering / Production Engineering / Industrial Engineering.
- Experience in BESS, battery pack, energy storage, EV, power electronics, electrical equipment, heavy engineering, or containerized systems preferred.
- Hands-on experience in new product industrialization and manufacturing process development.
- Experience in setting up or scaling a manufacturing line will be preferred.

7. Technical Skills

- BESS container manufacturing and assembly
- Manufacturing process development
- DFMA
- Lean Manufacturing
- Line balancing
- PFMEA & Control Plan
- APQP / NPI
- Root Cause Analysis
- Kaizen / Continuous Improvement
- 5S / VSM / Poka-Yoke
- Capacity planning
- Cycle-time and takt-time analysis
- Production layout planning
- Tooling & fixture development
- Engineering change management
- Basic understanding of electrical systems and BESS architecture
- MS Excel / PowerPoint
- ERP/MRP systems
- CAD knowledge will be an advantage

8.

Behavioral

Competencies

- Strong problem-solving and analytical ability
- Manufacturing-oriented mindset
- Leadership and team-management skills
- Strong cross-functional coordination
- Decision-making capability
- Ownership and accountability
- Good communication and presentation skills
- Ability to work under project and production timelines
- Continuous improvement mindset
- Solid shop-floor orientation

9. Preferred Industry Exposure

Candidates from the following industries may be considered:

- Battery Energy Storage Systems (BESS)
- Lithium-ion battery manufacturing
- EV / EV battery
- Power electronics
- UPS / inverter manufacturing
- Electrical panels / switchgear
- Renewable energy
- Containerized equipment
- Heavy engineering
- Industrial automation
- HVAC / fire protection systems

10. Overall Responsibility

The Manager – Manufacturing Engineering will be accountable for establishing robust, scalable, safe and cost-effective manufacturing processes for BESS containers, enabling successful product industrialization and achieving the organization's targets for quality, cost, delivery, productivity, capacity and safety.

📌 Manager (Pune)
🏢 SPML Infra
📍 Pune