Lead – Production (BESS) Full Time

Role Mandate

Suzlon is building a BESS business where the factory must behave like a product operation, not a “project workshop”

The BESS Manufacturing Lead will stand up, stabilize, and continuously improve Suzlon’s BESS pack assembly and containerization operations with takt-based planning, quality gates, full traceability, and strong EHS governance—so the BU can deliver a standardized, certifiable, warranty-ready product at competitive cost.

This role is a critical early hire and will own safety readiness, right-first-time quality, and predictable delivery.

Key Responsibilities

1. Brownfield integration & commissioning

• Lead retrofit and integration of new pack/container lines within an existing plant environment (layout, utilities, material flow, EHS zoning, storage and handling for Li-ion)
• Own plant infrastructure readiness for Li-ion operations: HV safety controls, zoning, emergency response preparedness, controlled storage, training & certification.
• Oversee FAT/SAT, installation, commissioning and performance acceptance of imported equipment with clear acceptance criteria and vendor accountability
• Deliver structured ramp-up to stable ~1.5 GWh capacity, with defined ramp gates (pilot builds → rate builds → steady state)

2) Industrialization & process stabilization

• Run pack assembly as a product operation: takt-based planning, standard work, quality gates, and traceability as non-negotiables
• Establish the “industrialization bridge” with CTO: DFM/DFA, process windows, CTQs, line balancing, and manufacturability-driven updates—while respecting CTO’s design/change authority
• Create a robust process engineering bench (lean but high impact) focused on yield/ramp-up and factory learning—not only running shifts (peer benchmark insight)

3. Manufacturing Operations & Multi-Shift Leadership

• Convert annual capacity targets into monthly/weekly/daily production plans with clear WIP controls and dispatch readiness gates.
• Implement scalable 2/3 shift operations with tiered daily management cadence (SQDC boards, tier reviews, escalation governance).
• Lead plant functions: Production, Industrial/Process Engineering, Quality, Maintenance/Utilities, Warehouse/Stores, and EHS

3. Quality, Compliance & EHS Governance

• Implement a manufacturing QMS suitable for Li‑ion operations: PFMEA, control plans, layered process audits, CAPA, deviation management, containment and MRB
• Build end-to-end traceability (cell → module → pack → container; test data retention; audit-ready documentation)
• Institutionalize high-voltage safety: HV work permits, LOTO, interlocks validation, arc‑flash practices, thermal incident response drills, safe storage and handling
• Ensure compliance readiness for applicable battery/BESS expectations (e.g., IEC/UL system safety norms as applicable; UN 38.3 transport readiness; Indian statutory requirements)
• Drive supplier quality management for external components (import + domestic): incoming quality gates, PPAP/qualification, supplier audits, corrective actions

4. Container Integration & System-Level Readiness

• Oversee mechanical, electrical and thermal integration into containerized systems; ensure robust grounding, interlocks, insulation/HV safety controls and safe routing
• Own end-of-line testing, validation evidence and dispatch documentation (traceability dossier + test certificates + FAT readiness packs)
• Interface with CTO/Engineering and Projects/EPC for controlled change management and design/process improvements (no uncontrolled deviations)

5. Planning, logistics & the Hybrid interface

• Own factory S&OP handshake: demand signal from BU/Wind BD, material readiness with Procurement, and dispatch alignment with EPC site schedules
• Define SLAs and escalation paths with shared Wind functions (Procurement/EPC/OMS) to ensure resourcing and decision speed

6. Cost, Productivity & Continuous Improvement

• Own conversion cost roadmap: labor productivity, yield/scrap, rework reduction, cycle time and line balance improvements
• Drive OEE improvements through TPM discipline: preventive maintenance adherence, spares strategy, uptime governance for imported equipment

Success Measures

Dimension – Measures

Capacity & delivery – Ramp milestones to stable ~1.5 GWh; throughput (MWh/month vs plan); OTIF dispatch; schedule adherence.

Operational excellence – OEE; First Pass Yield (FPY); cycle time reduction; labor productivity; stable takt achievement.

Quality & traceability – DPPM / defect rate; containment effectiveness; audit NCs and closure speed; full genealogy + test-data availability.

Safety – TRIR / LTIFR; HV safety compliance; near-miss closure discipline; emergency response drill readiness.

Cost & efficiency – Conversion cost per kWh; scrap & rework %; inventory turns; PM adherence and equipment uptime.

Candidate Profile

Experience & Background

• 8-12+ years in manufacturing leadership across battery pack/EV systems/power electronics/heavy electrical assembly/industrial product operations (hands-on plant leadership preferred)
• Demonstrated experience in setting up and stabilizing a new manufacturing line (industrialization + ramp-up + yield stabilization).
• Track record operating with rigorous quality systems, traceability, and safety governance in high-risk environments.
• Demonstrated ownership of plant-level KPIs (safety, quality, delivery, cost)

Domain Expertise (Must-Have)

• Strong understanding of pack/module assembly processes, quality gates, and typical failure modes (electrical isolation, connection integrity, thermal issues, workmanship variation)
• Familiarity with containerized BESS integration (mechanical fitment, electrical integration, system-level testing)
• Working knowledge of battery safety and regulatory frameworks (UL/IEC, UN 38.3, Indian compliance environment)
• Exposure to MES, traceability systems, and automated assembly environments
• Experience building plant cadence (daily management), continuous improvement, and problem-solving culture
• Working knowledge of Lean manufacturing and OEE-driven plant management

Education

• B.E./B.Tech in Mechanical / Electrical / Electronics / Industrial Engineering
• Postgraduate qualification in Operations/Manufacturing (MBA or equivalent) preferred