Module Lead- Manufacturing Engineering Process -Battery

the Team and the Role; Bengaluru; On-site; INR 1,500,000 - 2,200,000; Full time

Job summary

Ather Energy in Bengaluru seeks a seasoned Process Engineer to drive DFA/DFM, BOM development, and manufacturing integration for battery packs. You will lead value-improving projects, perform tolerance analyses, and implement CAPA and ECR processes to ensure robust assembly lines.

Join a high-velocity team that collaborates with design, quality, and production to optimize cycle times, reduce waste, and sustain safety and quality in a rapidly expanding electric vehicle program.

Qualifications

• Bachelor's or BE in Mechanical/Industrial engineering with 7–10 years of experience in high-volume battery assembly.
• Experience working in DFA/DFM and tolerance stack analyses on battery designs.
• Familiar with quality tools (FMEA, 8D) and IATF 16949 practices.

Responsibilities

• Focus on continuous improvement, maintenance, and optimization of battery assembly processes.
• Lead DFA/DFM analyses and tolerance stack studies for new designs.
• Develop and maintain BOMs and process definitions for manufacturing assembly.
• Conduct POC/DOE for process parameter finalization and CAPA implementation.
• Perform root cause analysis for defects and manage ECRs and PFMEA documentation.
• Drive Lean Six Sigma projects to reduce waste and improve cycle times.
• Collaborate with design, quality, and production teams to ensure successful integration.

Skills

Battery assembly

DFA/DFM

Tolerance analysis

DOE/POC

8D problem solving

Education

Bachelor's degree in Mechanical Engineering

Tools

AuroCAD

NX

SolidWorks

Job description

Role: Process Engineer

Location: IBC , Bengaluru

Reporting to: Lead - Manufacturing Engineering Process

Team Name: ME - Assembly

About the Team and the Role:

The Manufacturing Engineering Assembly team plays a pivotal role in attaining production and process excellence. As a Process Engineer, your duties will include: Ensuring Design for Assembly (DFA) Manufacturability: This involves conducting DFA analysis and Tolerance Stack studies specifically on battery designs. Process Definition: Developing the comprehensive Bill of Process for the manufacturing assembly operations. Technology Exploration: Investigating and implementing requisite technologies to fulfill product specifications. Proactive Design Input: Anticipating product design elements that will influence DFA and the overall manufacturing process. Design Integration: Incorporating manufacturing assembly hardpoints into the product design lifecycle.

Responsibilities:

• Focus on the continuous improvement, maintenance, and optimization of existing battery assembly processes.
• Evaluation of the battery pack design w.r.t design for assembly and manufacturability
• Exploring the technology for new battery pack design wherever applicable
• Proof of concept (POC) & DOE for process parameter finalization
• Tolerance stack analyse for the battery pack assembly
• Cost reduction projects implementation
• Monitor and analyze assembly line performance data to identify and address bottlenecks, quality issues, and efficiency gaps.
• Lead and implement continuous improvement projects using methodologies such as Lean Manufacturing and Six Sigma to reduce waste and improve cycle times.
• Point of contact for technical requirements which is required for manufacturing process design
• Conduct thorough root cause analysis for assembly defects, process deviations, and equipment malfunctions.
• 8D analysis for process related issues during the development build
• MBOM creation for all the new projects
• Implement effective corrective and preventive actions (CAPA) to resolve issues permanently.
• Manage the engineering change request (ECR) process for existing battery models, evaluating the impact on assembly processes, tooling, and cycle times.
• Ensure all engineering changes are properly documented, validated, and smoothly integrated into the production line.
• Maintain and update critical manufacturing documentation, including work instructions, process flow diagrams, and assembly sequences.
• Participate in the creation and revision of Process Failure Mode and Effects Analysis (PFMEA) and Design Failure mode and effect analysis,Control Plans for assembly operations.
• Ensure all processes and products adhere to safety standards, quality requirements, and legal regulations.
• Work closely with cross-functional teams, including design engineering, quality assurance, and production management, to solve problems and drive improvements.
• Designing of tools and Fixture for proto build

Experience and Qualifications:

B.Tech/BE or Bachelor’s degree in Engineering (Mechanical, Industrial, or a related field) with 7 to 10 years of experience.

Must have Competencies:

• Proven experience in a battery assembly or similar high-volume manufacturing environment.
• Hands-on experience with battery assembly processes
• Familiarity with quality management systems (e.g., IATF 16949) and quality tools (e.g., SPC, FMEA, 8D).
• Proficiency in reading and interpreting engineering drawings and CAD models.
• Better understanding of control systems
• Better understanding of battery manufacturing SPMs and troubleshooting

Good to have Competencies:

• APQP, Problem solving tools , MSA , GD&T and Tolerance stack
• Vismockup - Virtual manufacturing
• MPP planner - Digital work instruction
• AuroCAD,NX, Solidworks.

Want to know more?

At Ather, we’ve built India’s first intelligent scooter, from scratch. Based on the philosophy of clean design and smart technology, we are transforming the urban commute experience. We are expanding in India, and in the coming years, we look forward to scaling up and launching more products globally. Today, our product offerings include the Ather 450X, 450S, 450 Apex, and Rizta. Beyond the product, we are also setting up an extensive charging network and re-imagining end-to-end ownership experience. To know more, check out our Careers site and our Substack.

Be You, With Us.

The Ather story doesn't write itself - our people do. We believe everyone is equal, but not the same. Diversity is our strength, and building an inclusive and equitable workplace begins with acknowledging and embracing our differences. We are an equal opportunity employer, and our team reflects a wide range of identities, experiences, and perspectives - all united by a shared passion to shape the Ather journey.