Job Description (JD)

Associate Vice President – BESS Plant Operations

Department: Plant Operations | Industry: Battery Energy Storage System (BESS) | Level: Senior Management

1. Job Purpose

The Associate Vice President – BESS Plant Operations will be responsible for overall operational leadership, strategic planning, production management, and performance excellence of the BESS manufacturing plant. The role will ensure efficient plant operations, achievement of production targets, quality standards, cost optimization, safety compliance, and timely delivery of Battery Energy Storage Systems.

The incumbent will lead cross-functional teams to establish world-class manufacturing practices, improve operational efficiency, drive automation, and ensure business objectives are achieved in alignment with the organization's strategic vision.

2. Key Roles & Responsibilities

A. Overall Plant Operations

• Lead and manage end-to-end BESS plant operations, including manufacturing, assembly, testing, and dispatch.

• Develop annual operating plans, production strategies, and operational budgets.

• Ensure achievement of production targets, operational KPIs, and delivery commitments.

• Drive operational excellence, productivity improvement, and manufacturing efficiency.

• Establish robust systems for plant administration and operational governance.

B. Production & Manufacturing Management

• Oversee manufacturing of BESS containers, battery racks, modules, power conversion systems (PCS) integration, and associated electrical systems.

• Ensure effective production planning, capacity utilization, and resource optimization.

• Monitor manufacturing processes, line balancing, cycle time, and overall equipment effectiveness (OEE).

• Implement Lean Manufacturing, Six Sigma, Kaizen, 5S, and continuous improvement initiatives.

• Ensure smooth coordination between production, planning, engineering, and supply chain teams.

C. Quality Management

• Ensure adherence to defined quality standards and manufacturing specifications.

• Establish quality control systems at incoming material, in-process, and final inspection stages.

• Drive root cause analysis (RCA), CAPA, and reduction of rejection and rework.

• Ensure compliance with relevant BESS product standards, testing protocols, and customer specifications.

• Promote a zero-defect manufacturing culture.

D. Maintenance & Engineering

• Ensure preventive, predictive, and breakdown maintenance of plant machinery and equipment.

• Improve equipment reliability and minimize downtime.

• Drive automation, process engineering, and technological upgrades.

• Ensure proper maintenance of utilities, infrastructure, and production facilities.

E. Supply Chain & Inventory Management

• Coordinate with SCM, procurement, and logistics teams to ensure uninterrupted material availability.

• Optimize inventory levels, material consumption, and working capital.

• Ensure effective vendor coordination and timely material movement.

• Monitor material traceability and storage conditions, particularly for battery cells and critical electrical components.

F. EHS & Statutory Compliance

• Ensure implementation of stringent Environment, Health & Safety (EHS) practices.

• Establish safety protocols for battery handling, electrical testing, thermal runaway prevention, fire protection, and emergency response.

• Ensure compliance with applicable statutory, environmental, factory, and electrical safety regulations.

• Drive safety audits, risk assessments, and employee safety training.

G. Financial & Cost Management

• Develop and manage plant operating budgets and capital expenditure plans.

• Drive cost reduction through productivity enhancement and process optimization.

• Monitor manufacturing conversion costs, overheads, manpower costs, and material wastage.

• Improve plant profitability and operational contribution.

H. Leadership & Team Development

• Lead and mentor senior functional heads and plant leadership teams.

• Build a performance-driven and accountable work culture.

• Develop succession planning and leadership capabilities.

• Ensure effective coordination across Production, Quality, SCM, Maintenance, Engineering, HR, and EHS.

I. Testing, Commissioning & Dispatch

• Ensure effective execution of battery pack testing, container-level testing, electrical testing, and functional validation.

• Oversee Factory Acceptance Testing (FAT) and customer inspections.

• Ensure proper integration and validation of Battery Management System (BMS), Energy Management System (EMS), HVAC, fire detection, and suppression systems.

• Ensure products meet customer requirements and are dispatched within committed timelines.

• Establish systems for product traceability, documentation, and quality records.

3. Key Performance Indicators (KPIs)

The AVP – BESS Plant Operations will be evaluated based on the following parameters:

4. Educational Qualification

• Bachelor's Degree in Mechanical / Electrical / Electronics / Industrial / Production Engineering.

• Master's Degree in Engineering / Operations Management / Manufacturing Management / MBA will be preferred.

• Certification in Lean Manufacturing, Six Sigma, TPM, or operational excellence will be an added advantage.

5. Experience Required

• 18–25 years of overall experience in manufacturing and plant operations.

• Minimum 8–10 years in senior leadership positions managing large-scale manufacturing operations.

• Relevant experience in BESS, battery manufacturing, lithium-ion battery packs, energy storage systems, power electronics, or electrical equipment manufacturing.

• Proven track record of establishing, scaling up, and managing manufacturing facilities.

• Experience in handling large teams, plant budgets, production planning, quality, supply chain, and operational excellence.

• Exposure to greenfield and brownfield plant setup, capacity expansion, and automation projects.

6. Technical & Functional Competencies

• Strong understanding of BESS manufacturing processes and battery technology.

• Knowledge of Lithium-ion battery systems, Battery Management Systems (BMS), PCS, EMS, HVAC, and thermal management.

• Understanding of battery safety, thermal runaway prevention, fire protection, and emergency response systems.

• Knowledge of relevant standards and certifications, including IEC 62619, IEC 62933, UL 9540, UL 9540A, and applicable NFPA standards, subject to product configuration and applicable regulations.

GOV.UK+2

• Strong knowledge of manufacturing excellence, Lean, TPM, Six Sigma, and automation.

• Expertise in SAP / ERP, production planning, inventory management, and cost control.

• Strong understanding of statutory compliance, factory regulations, and EHS management.

7. Leadership & Behavioural Competencies

• Strategic thinking and business acumen.

• Strong decision-making and problem-solving abilities.

• Excellent leadership and team management skills.

• Effective stakeholder and cross-functional management.

• Strong negotiation and conflict-resolution skills.

• Result-oriented approach with a focus on operational excellence.

• Ability to manage business growth, operational challenges, and organizational transformation.

8. Reporting Structure

9. Key Deliverables

1. Establish and maintain world-class BESS manufacturing operations.

2. Achieve production targets with optimal resource utilization.

3. Ensure superior product quality and manufacturing reliability.

4. Drive continuous improvement and operational cost reduction.

5. Develop a strong second-line leadership team.

6. Ensure zero tolerance towards unsafe working practices.

7. Improve plant profitability and overall operational performance.

8. Support business expansion through manufacturing capacity enhancement.

10. Ideal Candidate Profile

An experienced manufacturing leader with strong exposure to BESS, battery manufacturing, or electrical equipment manufacturing, capable of independently managing end-to-end plant operations. The ideal candidate should have demonstrated expertise in plant leadership, production management, operational excellence, quality assurance, cost optimization, and people management, with the ability to scale manufacturing operations in line with business growth.