JOB DESCRIPTION

Head - BESS Container Manufacturing

Manufacturing Engineering, Process & Plant Setup

Parameter

Detail

Organisation

Mangal Industries Ltd (MIL) - Amara Raja Group

Business

BESS Metal Products - Container & Enclosure Manufacturing

Location

Andhra Pradesh, India (greenfield BESS container facility + existing Metal Fabrication plants)

Reports to

Operations Head / Business Head - BESS Metal Products

Level

Senior Manager / AGM / DGM (commensurate with experience)

Experience

12-20+ years, hands-on sheet metal, container fabrication, welding and plant setup

Employment type

Full-time, on-site (relocation required)

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Contents

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1. Recommended Job Title

Primary title:Head - BESS Container Manufacturing/BESS Container Manufacturing Expert

2. Position Summary

MIL is building a dedicated manufacturing capability for Battery Energy Storage System (BESS) containers and associated metal fabricated products. We are looking for a senior, hands-on manufacturing leader who has personally built, stabilised and scaled fabrication lines for containers or large outdoor enclosures, and who can do it again for BESS.

You will own the complete chain from design-for-manufacturing through forming, welding, blasting, painting, assembly, inspection and dispatch, and you will convert a BESS container design into a repeatable, cost-competitive mass-production system. This is a builder role on the shop floor, not a desk, project-coordination or battery-electrical role.

3. Business Context

MIL is an established metal fabrication company within the Amara Raja Group with in-house laser cutting, CNC punching, press brake bending, roll forming, welding, pretreatment and powder coating, serving demanding industrial customers. The group is expanding into BESS metal products to serve India's fast-growing energy storage market.

- Product scope:20-ft & 40-ft BESS container structural enclosure and internal mechanical systems (manufactured in-house), with fire and safety systems bought out and integrated.
- Out of scope for manufacture:cells, modules, BMS, PCS, EMS, HVAC packages and fire equipment. The role must, however, manage every mechanical interface to these systems.
- Scale ambition:a dedicated greenfield container line designed for high-volume output (planning basis in the order of 10 containers per day), alongside BESS cabinets, enclosures, rack structures and sub-assemblies from existing plants.
- Market context:Indian integrators and cell makers are commissioning large BESS container lines (for example, Waaree Energy Storage Solutions began production at its Gujarat BESS container facility in July 2026), creating demand for localised, high-quality container bodies.

4. Role Objective

Within 12-18 months, establish a BESS container manufacturing system that:

- Delivers containers meeting structural, dimensional, IP/weather-protection and corrosion requirements right first time.
- Runs at a defined takt with balanced stations, standard work, and a clear robotic/manual welding split.
- Achieves a competitive, known and continuously reducing manufacturing cost per container.
- Passes customer audits, FAT and first-article inspection, and scales without quality dilution.
- Is documented (PFD, PFMEA, Control Plan, WPS, SOP/WI) and can be run by the team without dependence on one individual.

5. Key Responsibilities

- Industrialisation:Convert BESS container and enclosure designs into production-ready process routes, tooling, fixtures and inspection plans.
- Process ownership:Own the end-to-end flow - raw material → cutting → forming → fabrication → welding → shot blasting → painting → assembly → inspection → packing → dispatch.
- Plant setup:Lead layout, machine selection, CAPEX estimation, equipment specification, vendor evaluation, FAT/SAT, installation, commissioning, trials and ramp-up.
- Welding leadership:Define welding strategy, WPS/PQR, welder qualification, robotic welding feasibility and distortion control.
- Surface & coating:Establish blasting and liquid paint systems that meet outdoor corrosion and durability requirements.
- Quality:Build PFMEA, Control Plans, inspection stages, critical characteristics and capability studies lead RCA/8D/CAPA.
- Cost & productivity:Drive cost per container, first-pass yield, welding productivity, paint consumption and labour productivity through Lean.
- DFM/DFA:Challenge designs that are difficult or expensive to make and propose practical alternatives with Design Engineering.
- People:Build and lead the manufacturing, process, welding, paint and quality teams develop supervisors and skilled welders.
- Cross-functional:Coordinate PPC, procurement, supplier development, stores, maintenance and tool room to hit launch and volume targets.

6. BESS Container Manufacturing Scope

Requirement level: MUST HAVE - container or large outdoor structural enclosure fabrication

Hands-on experience manufacturing the following (container structural fabrication experience is specifically sought):

Structure group

Components

Primary structure

BESS container structures (20 ft / 40 ft type), container frames, base frames, corner posts, top/bottom side rails, cross members, lifting structures

Envelope

Roof structures, side walls, end walls, doors, access panels, sealing-related interfaces, drainage and water-management features

BESS openings & interfaces

HVAC openings, cable entry structures, fire-system mounting structures, explosion/pressure-relief interfaces, earthing points

Internal structures

Battery rack supports, internal structural members, electrical equipment mounting structures, cable tray supports

Logistics structures

Transportation-related structural components, lashing points, forklift/crane lifting provisions, container accessories

7. Metal Forming Expertise

Requirement level: MUST HAVE - cutting, press brake and fixtures roll forming is STRONG PREFERENCE

- Cutting:Fibre laser cutting, CNC punching, shearing nesting and material utilisation.
- Forming:Press brake bending, panel bending, roll forming and profile manufacturing (corrugated panels, posts, rails, stiffeners), progressive or batch forming where applicable.
- Structural:Tube/pipe processing, structural member fabrication, corner/post/profile manufacturing, stiffener manufacturing.
- Tooling:Jigs and fixtures, forming tool development, dimensional control,



springback compensation.

Process selection capability:The candidate must demonstrate how they select the right process for each part based on volume, part geometry, material, thickness, tolerance, cost, cycle time and automation potential - for example, roll forming versus press-brake corrugation for side walls at different volumes.

8. Welding & Robotic Welding

Requirement level: MUST HAVE - this is the most critical competency for the role

- Processes:MIG/MAG (including pulsed), TIG where applicable, spot welding where applicable manual, semi-automatic and robotic welding.
- Equipment:Welding fixtures, positioners, manipulators, robotic welding cells, seam trackers and touch sensing.
- Engineering:Weld sequencing, heat input control, distortion control, parameter development, WPS development, PQR/WPQ awareness (ISO 15614 / AWS D1.1 / relevant IS codes).
- People & quality:Welder qualification, weld quality inspection, weld defect prevention, grinding and weld finishing, rework reduction.
- Automation strategy:Ability to assess robotic welding feasibility - part fit-up tolerances, fixture repeatability, weld accessibility, ROI - and to define the robotic/manual split. Operating robots alone is not sufficient.

9. Shot Blasting & Surface Treatment

Requirement level: MUST HAVE - practical understanding of surface prep for outdoor durability

- Shot and grit blasting, blast media selection, blast parameters, cleanliness grades (e.g., Sa 2½) and surface profile control.
- Pretreatment, rust prevention, corrosion protection, soluble salt and dust checks, surface inspection.
- Understanding of how surface preparation drives paint adhesion and the 20+ year outdoor life expected of BESS containers.

10. Liquid Painting

Requirement level: MUST HAVE - powder coating knowledge is an ADVANTAGE for internal components

- Industrial liquid painting:primer, intermediate and top coat systems suited to outdoor/corrosive environments (C4/C5 class).
- Application:Airless and conventional spray, paint booth operation, paint mixing, viscosity control, flash-off, curing and recoat intervals.
- Quality:DFT control, adhesion testing (cross-cut / pull-off), paint defect prevention and control.
- Cost:Paint consumption optimisation, transfer efficiency and theoretical versus practical spreading rates.

11. Assembly

Requirement level: MUST HAVE

- Structural, panel, door, roof and floor assembly.
- Battery rack assembly, HVAC mounting, electrical cabinet mounting, cable tray mounting, fire suppression interfaces.
- Sealing and gasketing, fasteners, riveting, bolting, torque-controlled assembly with records.
- Final inspection, leak/water-ingress prevention and testing, door alignment, packing and dispatch preparation.

12. Manufacturing Engineering

Requirement level: MUST HAVE

The role holder will personally develop or directly lead:

- Process documentation:Manufacturing process flow, process routing, process sheets, PFMEA, Control Plans, SOPs and work instructions.
- Time & capacity:Standard cycle times, takt time, line balancing, capacity calculations, bottleneck identification.
- Resources:Manpower, machine and tooling requirements welding fixtures and robotic welding concepts.
- Quality planning:Inspection stages, critical quality characteristics, process capability requirements, traceability.
- Improvement:Reduction of welding distortion, grinding and rework first-pass yield, productivity and cost improvement process KPIs and preventive quality controls.

13. DFM / DFA

Requirement level: MUST HAVE

Work closely with Design Engineering on DFM, DFA, GD&T;, weld design, sheet-metal design, bend allowance, welding/assembly/tool accessibility, manufacturing tolerances, part and fastener standardisation, material optimisation, weight reduction, cost reduction and automation feasibility.

Expectation:The candidate is expected to challenge designs that are difficult or expensive to manufacture and propose practical, validated alternatives - not simply build what is drawn.

14. Quality Responsibilities

Requirement level: MUST HAVE - ISO 9001 / 14001 / 45001 exposure is relevant

- Inspection system:Incoming, in-process, final, dimensional, weld and paint inspection.
- Container-critical characteristics:Flatness, squareness, parallelism, diagonals, door alignment, weld distortion, water ingress prevention and leak testing where applicable.
- Coating:DFT measurement, adhesion testing, corrosion protection verification.
- Tools:Root cause analysis, 8D, CAPA, FMEA, Control Plan, SPC, MSA.

15. Lean & Productivity

Requirement level: MUST HAVE - with quantified results from previous roles

5S, Kaizen, VSM, SMED, line balancing, takt time, standard work, OEE, waste elimination, productivity and manpower optimisation, scrap/rework/WIP reduction, bottleneck management and cost reduction. Candidates must evidence measurable before/after improvements.

16. Automation & Industry 4.0

Requirement level: SOLID PREFERENCE

Robotic welding, automated material handling, laser cutting automation, CNC bending, roll forming automation, welding positioners, conveyors, automated inspection, barcode/QR traceability, MES, production monitoring, OEE, Andon and manufacturing dashboards. Industry 4.0 implementation experience is an advantage.

17. New Plant / Capacity Expansion

Requirement level: MUST HAVE - at least one greenfield or brownfield line/plant setup

- Plant layout, process selection, automation strategy, machine selection and equipment specification.
- CAPEX estimation, vendor selection, supplier development.
- FAT/SAT, installation, commissioning, trial production, PPAP / production validation where applicable.
- Capacity ramp-up, SOP stabilisation and production launch.

18. Leadership Responsibilities

Lead or coordinate: Production, PPC, Manufacturing Engineering, Quality, Maintenance, Tool Room, Welding Engineering, Automation, Procurement, Supplier Development, Stores, Assembly, Paint/Surface Treatment and Design Engineering.



The role requires strong cross-functional leadership, visible shop-floor presence, and the ability to build a skilled team (welders, painters, fitters, supervisors) in a Tier-2/Tier-3 location.

19. Education & Experience

Item

Requirement

Level

Education

B.E./B.Tech - Mechanical / Production / Manufacturing Engineering

Must have

Alternate

Diploma with exceptional, proven hands-on experience

Case-by-case

Total experience

12-20+ years in fabrication manufacturing

Must have

Container / large enclosure

Minimum 5 years in container, E-house, genset canopy, CV body, rail car body or large outdoor enclosure fabrication

Must have

Plant / line setup

At least one end-to-end line or plant commissioning

Must have

BESS exposure

Direct BESS container or enclosure manufacturing

Solid preference

Certifications

Welding (IWE/IWT, CSWIP, AWS CWI), Lean/Six Sigma Green/Black Belt, quality engineering, PMP

Advantage

20. Must-Have Skills

- Sheet metal and structural fabrication of containers or large outdoor enclosures.
- MIG/MAG welding engineering, fixtures, distortion control, WPS/welder qualification.
- Robotic welding feasibility and cell concepting (not only robot operation).
- Shot blasting and liquid paint systems for outdoor corrosion protection, with DFT/adhesion control.
- Container assembly including doors, sealing and water-ingress prevention.
- PFMEA, Control Plan, SOP/WI, line balancing, takt, capacity and manpower calculations.
- DFM/DFA engagement with design teams.
- At least one line/plant setup through commissioning and ramp-up.
- Quantified Lean and cost-reduction results strong shop-floor leadership.

21. Good-to-Have Skills

- Direct BESS container / battery enclosure manufacturing.
- Roll forming line specification and tooling.
- Powder coating for internal components ISO 12944 / ISO 8501 practice.
- MES, QR traceability, OEE/Andon dashboards, Industry 4.0 projects.
- Exposure to UL 9540A / IEC 62933 driven customer requirements, ISO 1161 corner castings, CSC-type structural testing.
- SAP PP/QM usage for routings, work centres and inspection lots.
- Experience in Andhra Pradesh / South India Tier-2 locations and local skill development.

22. Key Performance Indicators

Indicative targets below are the planning basis final values will be fixed in the annual goal-setting after line stabilisation.

KPI

Definition / measure

Indicative target

Production output

Containers produced vs plan (daily/monthly)

≥ 98% plan adherence

On-time production

Containers ready vs committed dispatch date

≥ 95%

OEE

Laser, press brake, roll former, robot cells

≥ 75% on constraint equipment

Capacity utilisation

Actual vs rated line capacity

Per ramp-up curve

First Pass Yield

Containers passing final inspection without rework

≥ 95% at stabilisation

Rejection / Rework %

Rework hours ÷ total hours rejections by stage

Rework ≤ 3%

Welding productivity

Weld metres per welder-hour arc-on time %

Baseline + 20% in 12 months

Welding / assembly cycle time

Minutes per container per station vs takt

All stations ≤ takt

Paint quality & DFT compliance

Readings within spec adhesion pass rate

≥ 98% DFT compliance

Paint consumption

Litres per container vs theoretical

≤ 1.4× theoretical

Scrap %

Sheet/profile scrap ÷ consumption

≤ 2.5%

Manufacturing cost per container

Conversion cost (labour, consumables, energy, overhead)

Year-on-year reduction ≥ 8%

Labour productivity

Man-hours per container

Per ramp-up curve, then −10%/yr

New product launch time

Drawing release to first-article approval

Agreed per programme

CAPEX utilisation

Spend vs budget project milestones

Within ±5% of budget

Process capability

Cpk on critical dimensions (diagonals, door openings)

Cpk ≥ 1.33

Customer complaints

Field/customer complaints per 100 containers

Zero repeat complaints

Safety

LTIFR, near-miss reporting, hot-work compliance

Zero LTI

Target Talent Pool / Recommended Source Companies:

A. BESS / Energy Storage Manufacturers

Company

Location

Manufacturing relevance

Waaree Energy Storage Solutions (Waaree Energies)

Rola, Gujarat

Commenced BESS container manufacturing in July 2026 5.15 GWh facility with AGVs, automated assembly and testing

Jupiter Electric Mobility / Jupiter Wagons

Kolkata, Jamshedpur

10 ft and 20 ft containerised BESS built in-house from container fabrication to integration also ISO marine and specialty containers

Powertrac Group

Surendranagar, Gujarat

10 GWh BESS line ordered with an in-house container fabrication line production targeted Jan 2027 - target its setup team

Ddev Plastiks Industries

Gujarat

5 GWh BESS plant stated capacity of up to four 5 MWh containers per day

AmpereHour Energy

India

Opened 5 GWh factory (July 2026) for containerised and cabinet DC/AC blocks

SilicIndia Energies

Mandvi, Surat

Cell-to-40 ft container integration facility (company-reported)

Exide Industries / Exide Energy Solutions

Bengaluru, Kolkata

Lithium-ion expansion including stationary storage

APPL Containers (BESS range)

Bhavnagar, Gujarat

Makes BESS containers alongside ISO containers

International: Tesla (Megapack), Fluence, Sungrow, Hithium, CATL, BYD, Wärtsilä

Global / China / US

Target Indian engineers in their enclosure supply chains or Indian operations strongest for BESS-specific interface knowledge

International: Jabil (Rayong, Thailand)

Thailand

BESS metal enclosure plant covering sheet metal, structural welding and coating

B. Industrial Container Manufacturers

Company

Location

Manufacturing relevance

APPL Containers

Bhavnagar, Gujarat

ISO 20/40 ft, high cube, BESS and tank containers 15,000+ per year

Braithwaite & Co. (Ministry of Railways PSU)

Angus Works, Hooghly, WB

ISO and dwarf container manufacturing with dedicated 20/40 ft infrastructure

Jupiter Wagons - Containers

Kolkata / Jamshedpur

Marine, reefer, truck-mounted and specialty BESS containers

DCM Hyundai AB Sea Container

India

Named among notable Indian container manufacturers AB Sea also makes modular containers and shelters

MetalSquare

India

E-houses / containerised substations on welded I-beam bases

Pressmach Infrastructure

India

Prefabricated E-houses, pre-assembled and pre-tested

International: CIMC, Singamas, CXIC, Dong Fang

China / Asia

World-scale container and special container lines source India-returning engineers

📌 Head - Manufacturing Operations (India)
🏢 Amara Raja Group
📍 India