Purpose of the Role
Manage the Formation team on the Pilot Line to execute trial builds and chemistry changeovers (e.g., LFP to NMC or other emerging chemistries), achieving trial-run SQDC KPIs. Organize and control Formation process operations Electrolyte Injection, HT Baking, Ageing, Laser welding, EOL Testing including manpower deployment and line management within the shift. Handle process/quality abnormalities and exceptions, driving problem solving using the organisation's standard problem-solving tools.
Coordinate with R&D, Quality, and the Pilot Line Manager to align Formation-zone trial plans, changeover schedules, and production deliverables. Ensure timely data inputs are captured in MES/SAP to drive data-based decisions. Ensure full compliance to statutory, safety, and quality requirements (including IATF 16949), timely disposal of waste per set standards, and effective handling of non-standard procurement/consumables needed for trial builds.
Key Responsibility Areas
Greenfield
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Support execution of chemistry changeovers on the Formation Pilot Line — adjusting Electrolyte Injection, HT Baking, Ageing, and EOL Testing parameters (e.g., formation voltage/current profile, bake temperature, ageing duration, electrolyte formulation) for each new chemistry with minimal downtime.
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Support qualification of new cell designs, materials, and process parameters on the Pilot Line ahead of scale-up to mass production; capture DOE trial data and document changeover process windows for technology transfer to the Gigafactory line.
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Work closely and collaborate with CFTs process engineering (global/advanced PE and plant PE, ME), R&D, Quality, construction, HR, Maintenance to ensure the right physical and operational standards are in place for pilot-line trials.
Knowledge Generic
Essential - 5–10 years leading Production/pilot-line operations in Li-ion cell, EV battery pack, or solar cell manufacturing, with NPI, process validation, or multi-chemistry changeover exposure. Strong knowledge of Formation operations (Electrolyte Injection, HT Baking, Ageing, Laser welding, EOL Testing) and how parameters shift across chemistries. skilled in exception/NG/CAPA handling and problem-solving tools (8D, Six Sigma, 7 QC, 5-Why, Fishbone, FMEA, DOE). Working knowledge of IATF 16949, SAP/ERP, and MES. Proven cross-functional coordination with R&D and Quality to execute the Formation Pilot Line plan. Hands-on manpower/line management, safety leadership, and non-standard procurement/consumables handling
Job Context
Functional
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Ensure physicals like SOPs/WI/Check sheets are ready and well understood by Team Leaders/Operators and updated for each chemistry changeover.
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Ensure Formation Pilot Line throughput is as per trial plan and issues are timely escalated.
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Plan and manage manpower deployment and line management within the shift, including attendance, work allocation, and multi-skilling to support changeover-driven workload swings.
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Drive a strong safety culture on the shop floor — safety compliance, PPE discipline, risk assessments, and incident/near-miss reporting for the Formation Pilot Line, including chemistry-specific handling considerations.
Job Context Specific
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Manage non-standard procurement and consumables required for trial builds (trial materials, spares, tooling, chemistry-specific PPE), coordinating with Maintenance/SCM to avoid trial downtime.
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Ensure 100% compliance to all statutory, safety, and quality-management-system requirements, including IATF 16949.
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Log and track production, quality, and changeover data in SAP and MES, ensuring accurate real-time shop-floor data capture for traceability and reporting.
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Drive problem solving using the full range of standard tools 8D, Six Sigma, 7 QC Tools, 5-Why, Fishbone/Ishikawa, FMEA — and manage NG products.
Knowledge Specific
Role Specific Qualifications/Certifications
B.E in (Electrical /Chemical), Six Sigma Certified
