Lead - Production (BESS)

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

Brownfield integration & commissioningLead 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 accountabilityDeliver structured ramp-up to stable 1.5 GWh capacity, with defined ramp gates (pilot builds rate builds steady state)

• Industrialization & process stabilization

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

• Manufacturing Operations & Multi-Shift LeadershipConvert 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
• Quality, Compliance & EHS GovernanceImplement a manufacturing QMS suitable for Li ion operations: PFMEA, control plans, layered process audits, CAPA, deviation management, containment and MRBBuild 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 handlingEnsure 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
• Container Integration & System-Level ReadinessOversee mechanical, electrical and thermal integration into containerized systems; ensure robust grounding, interlocks, insulation/HV safety controls and safe routingOwn 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)
• Planning, logistics & the Hybrid interfaceOwn factory S&OP handshake: demand signal from BU/Wind BD, material readiness with Procurement, and dispatch alignment with EPC site schedulesDefine SLAs and escalation paths with shared Wind functions (Procurement/EPC/OMS) to ensure resourcing and decision speed
• Cost, Productivity & Continuous ImprovementOwn conversion cost roadmap: labor productivity, yield/scrap, rework reduction, cycle time and line balance improvementsDrive 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 & Background8-12+ 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 environmentsExperience building plant cadence (daily management), continuous improvement, and problem-solving cultureWorking knowledge of Lean manufacturing and OEE-driven plant management

EducationB.E./B.Tech in Mechanical / Electrical / Electronics / Industrial EngineeringPostgraduate qualification in Operations/Manufacturing (MBA or equivalent) preferred