Proto Pilot Mechanical/Electrical

VSL PowerHive · India

Job Description – Proto/Pilot Senior Manager (Mechanical & Electrical) – BESS

Role Summary

The Proto/Pilot Senior Manager – Mechanical & Electrical (BESS) will lead prototype development, pilot production, mechanical and electrical integration, validation support, and manufacturing readiness for Battery Energy Storage System (BESS) products at a 5 GWh / 6.25 GWh manufacturing facility .

The role will act as a critical bridge between Engineering, Validation, Quality, Supply Chain, and Manufacturing to ensure successful transition from prototype development to pilot production and scalable mass manufacturing.

Key Job Responsibilities

Prototype & Pilot Build Leadership

• Lead end-to-end prototype and pilot build activities for BESS products.
• Manage engineering builds, design validation builds, pre-production builds, and pilot production builds.
• Develop and execute prototype build plans, schedules, resource requirements, and milestones.
• Drive rapid problem-solving and design iterations during prototype and pilot stages.
• Ensure prototype builds are completed within defined timelines, quality, safety, and cost targets.
• Lead teams of engineers, technicians, and manufacturing personnel involved in prototype and pilot builds.

Mechanical Prototype & System Integration

• Lead mechanical integration of battery modules, packs, racks, enclosures, and containerized BESS systems.
• Oversee assembly of structural frames, battery housings, cooling systems, mechanical interfaces, and related components.
• Identify and resolve mechanical fitment, tolerance, interference, fastening, sealing, and structural issues.
• Ensure proper mechanical integration across the complete BESS architecture.
• Support thermal and cooling system integration, including interfaces between mechanical and thermal components.
• Drive Design for Manufacturability (DFM) and Design for Assembly (DFA) improvements.
• Work with mechanical design teams to incorporate prototype and pilot build learnings into future product revisions.
• Support tooling, fixture, jig, and assembly process development for mechanical manufacturing.

Electrical Prototype & System Integration

• Lead electrical prototype and pilot builds for battery modules, packs, racks, and complete BESS systems.
• Oversee integration of high-voltage and low-voltage electrical systems.
• Manage assembly and integration of busbars, cables, connectors, contactors, fuses, relays, sensors, and wiring harnesses.
• Ensure proper electrical integration from Cell → Module → Pack → Rack → System → Container .
• Coordinate BMS, communication, control, auxiliary power, grounding, and bonding interfaces.
• Support integration with power electronics and external system interfaces.
• Identify and resolve electrical interconnect, wiring, insulation, grounding, communication, and BMS-related issues.
• Ensure compliance with electrical safety and HV assembly requirements.
• Support development of electrical work instructions, assembly standards, inspection criteria, and testing procedures.

Pilot Production Management

• Lead pilot-scale manufacturing activities and ensure pilot line readiness.
• Develop and optimize assembly sequences and production processes.
• Support pilot line setup, station design, material flow, and operator readiness.
• Develop standard work instructions and operating procedures.
• Drive cycle time reduction and throughput improvement.
• Support line balancing and manpower optimization.
• Improve first-pass yield and reduce scrap, rework, and process variation.
• Identify manufacturing bottlenecks and implement corrective actions.
• Ensure pilot processes are stable and repeatable before mass production transfer.
• Support production ramp-up for the 5 GWh / 6.25 GWh BESS manufacturing facility.

Issue Resolution & Root Cause Analysis

• Lead troubleshooting of prototype, pilot, mechanical, electrical, thermal, and manufacturing issues.
• Investigate failures related to mechanical fitment, electrical connections, thermal performance, assembly quality, and process variation.
• Conduct structured root cause analysis using tools such as:
• 5 Why Analysis
• Fishbone Diagram
• 8D Problem Solving
• FMEA
• Drive corrective and preventive actions with Engineering, Quality, and Manufacturing teams.
• Track critical issues until permanent resolution and closure.
• Develop lessons learned from prototype and pilot builds.

Validation & Design Improvement

• Work closely with validation and reliability teams during prototype and pilot testing.
• Support functional, performance, safety, and reliability validation.
• Coordinate mechanical, electrical, thermal, and system-level validation activities.
• Support electrical safety testing, insulation resistance, continuity, grounding, and BMS functionality testing.
• Support mechanical durability, vibration, structural, and thermal performance assessments.
• Analyze validation failures and provide manufacturing and engineering feedback.
• Ensure prototype learnings are incorporated into product design improvements.
• Support engineering changes and product design releases.

Manufacturing Process Development

• Collaborate with Manufacturing Engineering to develop scalable assembly processes.
• Support development of tooling, fixtures, jigs, and error-proofing solutions.
• Establish process controls and quality checkpoints.
• Develop manufacturing work instructions and standard operating procedures.
• Improve assembly ergonomics, material presentation, and workstation efficiency.
• Support automation and semi-automation opportunities where applicable.
• Ensure prototype and pilot processes are suitable for high-volume manufacturing.
• Drive improvements in yield, cycle time, productivity, and manufacturing efficiency.

Cross-Functional Coordination

• Work closely with Mechanical Design Engineering.
• Coordinate with Electrical and HV/LV Engineering teams.
• Partner with BMS and Controls Engineering teams.
• Collaborate with Thermal Management Engineering.
• Interface with Testing, Validation, Quality, and Reliability teams.
• Coordinate with Manufacturing Engineering and Operations.
• Work with Supply Chain and Sourcing for prototype and pilot material availability.
• Support supplier issue resolution and component quality improvement.
• Participate in cross-functional design reviews and manufacturing readiness reviews.

Team & Program Management

• Lead and mentor prototype and pilot engineers, technicians, and build teams.
• Manage multiple prototype and pilot programs simultaneously.
• Develop build schedules and resource plans.
• Track program milestones, deliverables, and technical risks.
• Ensure effective communication between engineering and manufacturing functions.
• Escalate critical program, technical, quality, and manufacturing risks.
• Drive a strong culture of safety, quality, accountability, and continuous improvement.

Required Qualifications

Education

• Bachelor's or Master's degree in:
• Mechanical Engineering
• Electrical Engineering
• Electronics Engineering
• Mechatronics Engineering
• Manufacturing Engineering
• Energy Systems
• Related Engineering Discipline

Experience

• 8–15+ years of relevant experience in BESS, lithium-ion batteries, EV, automotive, power electronics, renewable energy, or advanced manufacturing.
• Strong experience in prototype and pilot build management.
• Experience in battery pack, battery rack, or complete BESS system integration.
• Experience in mechanical and/or electrical manufacturing processes.
• Experience in transitioning products from prototype to pilot and mass production.
• Experience with large-format lithium-ion battery systems is highly preferred.
• Experience in LFP battery systems will be an added advantage.

Mandatory Technical Skills

• Prototype and pilot manufacturing processes.
• BESS and battery pack system integration.
• Mechanical and electrical assembly fundamentals.
• HV and LV system understanding.
• Manufacturing process development.
• Root cause and failure analysis.
• Design for Manufacturability (DFM).
• Design for Assembly (DFA).
• FMEA and structured problem-solving.
• Tooling and fixture development.
• Work instruction and SOP development.
• Pilot line setup and process stabilization.

Preferred Skills

• LFP-based BESS systems.
• BMS integration and communication systems.
• Thermal management and cooling systems.
• High-voltage electrical safety.
• Power electronics and PCS interface understanding.
• Process optimization and line balancing.
• Reliability and validation experience.
• Automated or semi-automated manufacturing.
• High-volume battery manufacturing and production ramp-up.

Key Performance Indicators (KPIs)

• Prototype build cycle time.
• Prototype and pilot first-pass yield.
• Pilot production yield and throughput.
• Scrap and rework reduction.
• Issue resolution turnaround time.
• Design iteration efficiency.
• Assembly cycle time improvement.
• Process stability and repeatability.
• Manufacturing readiness for mass production.
• Successful pilot-to-production transfer.
• Achievement of 5 GWh / 6.25 GWh production ramp-up targets.
• Product robustness, quality, and manufacturability.