BESS Manufacturing Engineer

Larsen & Toubro; Coimbatore District; On-site; INR 4,000,000 - 7,000,000; Full time

Job summary

Larsen & Toubro seeks a seasoned Lead/Head of Manufacturing Engineering to own end-to-end industrialization for high-volume vehicle and battery assembly lines in India. You will drive NPI from POC to mass production, architect scalable processes, and steer automation and digital manufacturing initiatives.

You will lead 20+ engineers, manage cross‑functional teams with R&D, Quality, and Supply Chain, and ensure robust safety, productivity, and quality metrics across multiple facilities.

Qualifications

• Master's or equivalent in Manufacturing/Mechanical/Industrial Engineering or related field.
• Bachelor's in Mechanical Engineering or equivalent required.
• 10+ years of progressive Manufacturing Engineering experience in automotive/EV/battery/industrial automation sectors.

Responsibilities

• Lead NPI from PoC to mass production with DFA/DFM/PFMEA/PPAP.
• Design scalable, modular manufacturing processes for multi-variant production.
• Own end-to-end process flow design, line balancing, takt time, ergonomics.
• Drive factory setup, capacity ramp‑up, and equipment commissioning with CAPEX ownership.
• Define automation strategy using PLCs, robots, vision systems, and testers; enable MES-PLC integration.

Skills

First-principles problem solving

Execution excellence

Leadership

Cross-functional collaboration

Education

Master's degree in Manufacturing / Mechanical / Industrial Engineering

Bachelor's degree in Mechanical Engineering

Tools

SolidWorks

Pro-E

AutoCAD

Inventor

MATLAB

Studio 5000

Ignition SCADA

Job description

Lead / Head - Manufacturing Engineering

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