Lead Manufacturing Engineer - Battery and Vehicle Assembly

BESS Manufacturing Engineer

Lead / Head – Manufacturing Engineering

Role Summary

We are seeking a highly experienced Manufacturing Engineering leader to drive industrialization, factory setup, automation, and continuous improvement across high-volume, technology-driven manufacturing environments. The role involves end-to-end ownership of New Product Introduction (NPI), process design, automation strategy, and team leadership across vehicle and battery assembly operations.

This position requires strong first-principles thinking, hands-on engineering depth, and the ability to lead cross-functional teams in fast-paced, resource-constrained environments.

Key Responsibilities

Manufacturing & Industrialization

• Lead New Product Introduction (NPI) from Proof of Concept (POC) through mass production, ensuring robust DFA, DFM, PFMEA, and PPAP execution.
• Design and implement scalable, modular, and flexible manufacturing processes to support multi-variant production.
• Own end-to-end process flow design, line balancing, takt time optimization, and ergonomics.
• Drive factory setup and capacity expansion, including commissioning of vehicle and battery assembly lines.
• Manage capital equipment projects, including SPMs, robotics, conveyors, AGVs, and automated testing systems, with CAPEX responsibility.

Automation & Digital Manufacturing

• Define and implement automation strategy using SCARA robots, PLC-controlled machines, DC torque tools, vision systems, and functional testers.
• Enable MES–PLC integration to support traceability, poka-yoke systems, and multi-model manufacturing.
• Collaborate with digital transformation teams on MES, SCADA, and IoT-based productivity monitoring systems.
• Standardize machine design specifications covering safety, controls architecture, BOMs, and connectivity.

Continuous Improvement & Quality

• Drive Lean Manufacturing and Kaizen initiatives to improve productivity, quality, and cost.
• Apply advanced problem-solving tools such as A3, DMAIC, Root Cause Analysis, PFMEA, and EFMEA.
• Improve key metrics including takt time, RFT, productivity, and Value-Added Ratio (VAR).
• Lead robustness improvements for processes involving welding, dispensing, torqueing, and testing.

Leadership & Team Management

• Build, mentor, and lead cross-functional manufacturing engineering teams (20+ engineers).
• Define clear roles, responsibilities, and competency development plans.
• Foster strong collaboration with R&D, Quality, Supply Chain, Operations, and External Vendors.
• Manage and develop technical talent to support current production and future growth.

Stakeholder & Vendor Management

• Work with global suppliers and OEMs for machine development, benchmarking, and commissioning.
• Lead vendor selection, technical specification definition, FAT/SAT, and commissioning activities.
• Manage internal and external stakeholders across multiple geographies.

Required Qualifications

Education

• Master’s degree in Manufacturing / Mechanical / Industrial Engineering or related field.
• Bachelor’s degree in Mechanical Engineering or equivalent.

Experience

• 10+ years of progressive experience in Manufacturing Engineering within automotive, EV, battery, or industrial automation environments.
• Proven experience in:
  • Vehicle and/or battery pack manufacturing
  • Factory setup and capacity ramp-up
  • High-volume automated lines
  • NPI and industrialization projects
• Demonstrated people leadership experience managing medium to large engineering teams.

Technical Skills

• Manufacturing processes: Assembly systems, battery pack assembly, welding, dispensing, fastening, and testing.
• Automation & Controls: PLCs (Allen-Bradley), SCARA robots, DC torque tools, vision systems, AGVs.
• Digital systems: MES, SCADA (Ignition), IoT, data analytics.
• Design & Engineering tools: SolidWorks, Pro-E, AutoCAD, Inventor, MATLAB.
• Quality & CI tools: PFMEA, EFMEA, PPAP, GD&T, Six Sigma, Lean Manufacturing.
• Software/Controls: Studio 5000, Unity Pro, Ignition.

Key Competencies

• First-principles problem solving
• Strong execution and ownership mindset
• Strategic yet hands-on leadership
• Operations-oriented decision making
• Ability to thrive in fast-scaling, ambiguous environments
• Excellent stakeholder communication and influence

Preferred Background

• Experience in EV, battery manufacturing, or automotive OEMs
• Exposure to global manufacturing operations
• Track record of building greenfield facilities or major expansions