Head – Manufacturing Engineering / VP – BESS Operations

Role Summary

The Head – Manufacturing Engineering / VP – BESS Operations will lead the complete manufacturing strategy, operations planning, technology roadmap, team structure, supply chain coordination, safety governance, and compliance for lithium-ion battery cell-to-pack and containerized BESS battery banks used in grid-scale storage.

This leadership role drives plant capability, automation, yield, quality, vendor ecosystem, product reliability, and cost competitiveness, aligned with global benchmarks and utility-grade safety standards.

Core Leadership Responsibilities

1. Technology & Process Leadership

• Define and own the manufacturing architecture for cell, module, pack, and containerized BESS bank.
• Drive process design, automation, digitalization, Industry 4.0 implementation (MES/SCADA integration), and traceability systems.
• Approve PFMEA/PFD/Control Plans/PPAP/SOP frameworks for all plants.
• Lead tech selection for welding, formation, thermal management, fire systems, HVAC, gas venting, inspection automation, and battery testing.

2. Global Standards, Safety & Compliance Governance

• Ensure compliance to worldwide BESS standards: UL 9540/9540A, UL 1973, IEC 62933, IEC 62619, UN38.3, NFPA 855, NFPA 70/70E, NFPA 72, local CEA norms.
• Govern EHS strategy covering MSDS, lithium fire hazards, gas management, explosion prevention, arc-flash mitigation, HV safety protocols.
• Oversight for HAZOP, HIRA, DFMEA, PFMEA, Fire Risk Assessments, HVIL systems, cell/pack abuse testing, and runaway prevention.

3. Strategic Operations & Cost Ownership

• Design and expand plants based on BESS demand projections and localization strategy.
• Own CapEx/OpEx budgets, vendor development, outsourcing strategy, and cost optimization.
• Approve sourcing and localization for cells, thermal systems, HV DC components, BMS/EMS/PCS interfaces, fire suppression, HVAC units, and containerized infrastructure.
• Direct (EV vs BESS) chemistries sourcing strategy (LFP/NMC/LTO) with focus on cycle life, safety, and economics.

4. Quality, Reliability & Testing Governance

• Approve reliability test matrices & qualification strategies for:
• Long-cycle aging & RTE performance
• Stress, C-rate & high-temperature cycling
• Thermal propagation & abuse testing
• Bank fault simulation & fail-safe testing
• Utilize real-time diagnostic analytics based on SCADA/MES logs to prevent field failures.
• Implement quality systems (ISO 9001, IATF 16949, ISO 14001, ISO 45001 as applicable).

5. Organizational & Vendor Ecosystem Development

• Build and lead a multi-disciplinary organization, including:
• Manufacturing Engineering
• Thermal & Mechanical Engineering
• BMS/Controls/SCADA/EMS Engineering
• EHS/Safety and Certification
• Commissioning & Aftermarket
• Develop an ecosystem of domestic/international suppliers & technology partners.
• Create skill development frameworks for technicians → engineers → leaders.

6. Cross-Functional & Business Leadership

• Collaborate with R&D, Product Management, EPC/Project Delivery, Commissioning, and After-Sales for bank reliability and commissioning success.
• Drive customer audits, certification approvals, EPC specifications alignment, and performance warranties (availability, RTE, duty cycle guarantees).
• Support commercial teams in technical bids, tenders, and techno-commercial evaluations for C&I, utility, and renewable-integrated BESS projects.

Qualifications & Experience

Bachelor’s degree (B.E./B.Tech) mandatory; Master’s Degree (M.Tech or MBA in Operations/Strategic Leadership) preferred.

• 15–25 years of experience with extensive exposure to:
• Li-ion manufacturing (EV Packs/BESS)
• Utility-grade electrical systems & compliance
• HV battery operations (600–1500 V DC)
• Plant leadership, CapEx planning, automation, & vendor development
• Prior leadership role (Head/GM/VP level) in ESS, EV batteries, Power Electronics, Renewable EPC, or High-Reliability Manufacturing preferred.

Key Competencies

• Leadership & Strategy
• Visionary mindset with deep understanding of global energy storage trends.
• Strong governance on safety, compliance, quality, reliability, and documentation.
• Ability to lead multi-plant operations & scaling strategies.

Technical & Business Skills

• Expert in lithium battery safety, thermal management, BMS hierarchy, HV compliance, and containerized BESS integration.
• High competency in CapEx/Opex planning, localization strategy, total cost of ownership (TCO), and power market implications.

Soft Skills

• Excellent communication with internal teams, board members, regulatory bodies, EPCs, utilities, and certification agencies.
• Stakeholder management, negotiation, team building, and conflict resolution.