Manufacturing Engineering Lead - BESS

Manufacturing Engineering Lead - BESS

Head - Manufacturing (BESS: C&I & Utility Scale) Position Summary The Head of Manufacturing will lead end-to-end manufacturing operations for Battery Energy Storage Systems (BESS) catering to Commercial & Industrial (C&I) and Utility-scale energy storage applications. The role will be responsible for driving manufacturing excellence across battery module assembly, battery packs, racks,BMS, containerised BESS integration, power conversion system (PCS) integration, testing, quality, supply chain coordination, and project delivery readiness. The incumbent will be instrumental in scaling operations from current manufacturing levels to gigawatt-hour-scale production while ensuring world-class quality, safety, productivity, and cost competitiveness. Key Responsibilities Manufacturing Leadership • Develop and execute manufacturing strategy aligned with business growth objectives. • Lead manufacturing operations for: o Battery modules o Battery packs o Battery racks o Containerised BESS systems o Integrated PCS and energy management systems • Establish scalable manufacturing processes for C&I and utility-scale projects. • Drive operational excellence through Lean Manufacturing, Six Sigma and Industry 4.0 initiatives. • Build a high-performance manufacturing organisation and leadership pipeline. Production Planning & Execution • Ensure achievement of production targets related to: o Capacity o Cost o Quality o Delivery o Productivity • Optimise manufacturing throughput and capacity utilisation. • Develop annual manufacturing plans and expansion roadmaps. • Lead commissioning and ramp-up of new manufacturing lines and facilities. BESS System Integration • Oversee manufacturing of: o Battery enclosures o Battery racks o DC systems o PCS integration o EMS/SCADA integration o Containerised BESS solutions • Ensure compliance with: o IEC standards o UL standards o NFPA requirements o Grid-code requirements o Customer specifications • Collaborate with engineering teams for design-for-manufacturing (DFM) and design-for-assembly (DFA). Quality & Reliability • Develop robust quality management systems. • Ensure compliance with ISO 9001, ISO 14001 and ISO 45001 standards. • Drive: o First-pass yield improvement o Defect reduction o Warranty reduction o Reliability enhancement • Lead root-cause analysis and corrective action programmes. EHS Leadership • Establish a safety-first manufacturing culture. • Ensure compliance with all statutory and regulatory requirements. • Implement battery handling and energy storage safety protocols. • Lead emergency preparedness and fire safety initiatives for lithium-ion and advanced battery technologies. Supply Chain & Vendor Development • Work closely with procurement and supply chain teams to ensure uninterrupted material availability. • Develop strategic partnerships with suppliers for: o Cells o PCS o Battery Management Systems o Thermal management systems o Power electronics o Structural components • Establish supplier quality management programmes. Cost Optimisation • Drive manufacturing cost reduction initiatives. • Improve: o Labour productivity o Material utilisation o Overall Equipment Effectiveness (OEE) o Inventory turns • Identify localisation opportunities for critical subsystems and components. Capacity Expansion & New Programmes • Lead greenfield and brownfield expansion projects. • Support introduction of emerging battery technologies including: o LFP o LMFP o Sodium-Ion o Future battery chemistries • Develop manufacturing readiness plans for new products. Cross Functional Leadership • Work closely with: o Engineering o R&D o Product Management o Quality o Supply Chain o Projects o Service to ensure seamless execution of customer projects. Key Performance Indicators (KPIs) • Manufacturing capacity utilisation • Production output (MWh/GWh) • OEE • On-time delivery • Manufacturing cost per kWh • First-pass yield • Scrap and rework reduction • Warranty cost reduction • Safety performance (LTIFR) • Inventory turns • EBITDA contribution from operations Qualifications Education • B.E./B.Tech in Electrical, Electronics, Mechanical, Industrial Engineering or related discipline. • Master’s degree in engineering or Operations Management preferred. • MBA preferred. ________________________________________ Experience Essential • 20+ years of manufacturing experience. • Minimum 5 years in leadership roles managing large manufacturing operations. • Proven experience in one or more of: o BESS manufacturing o Battery manufacturing o Power electronics manufacturing o Inverter manufacturing o EV battery pack manufacturing o Renewable energy equipment manufacturing Preferred • Experience in utility-scale energy storage projects. • Experience in containerised BESS manufacturing. • Exposure to gigafactory or large-scale battery manufacturing environments. • Experience setting up new manufacturing plants or production lines. Technical Competencies Strong Understanding Of • Battery technologies: o LFP o LMFP o NMC o Sodium-Ion • Battery Management Systems (BMS) • Power Conversion Systems (PCS) • Energy Management Systems (EMS) • SCADA integration • Thermal management systems • HV & LV electrical systems • Grid-connected energy storage systems Manufacturing Tools • Lean Manufacturing • Six Sigma • TPM • Kaizen • APQP • PFMEA • SPC • MES systems • ERP platforms (SAP, Oracle, Microsoft Dynamics) Leadership Competencies • Strategic thinking • Execution excellence • Team building • Change management • Stakeholder management • Commercial acumen • Problem-solving capability • Customer orientation • Continuous improvement mindset Ideal Candidate Profile A seasoned manufacturing leader with a strong background in battery energy storage systems, power electronics, or advanced energy technologies, capable of building a world-class manufacturing organisation that delivers safe, reliable, and cost-competitive BESS solutions for C&I and utility-scale markets. Target Industries • Battery Energy Storage Systems (BESS) • Battery Cell Manufacturing • EV Battery Manufacturing • Solar Inverter Manufacturing • UPS Manufacturing • Renewable Energy Equipment • Grid Infrastructure Equipment