About the job
Role: Facility & Tooling Engineer – Battery Assembly
Location: Hosur Battery Factory
Location: Battery & Box Build Assembly – F&T Lead
Team Name: Manufacturing Engineering- Assembly
About the Team and the Role:
You will be responsible for designing, developing, and deploying advanced control strategies and Line development that not only rely on traditional methods but also leverage data-driven insights to optimize performance, predict failures, and automate complex processes. In this role, you’ll be at the forefront of integrating cutting-edge artificial intelligence (AI) and machine learning (ML) techniques into our control systems
Responsibilities:
Equipment, Facility and System design Development/Management:
- Design, develop, and integrate Programmable Logic Controller (PLC – Siemens and Mitsubishi), Human-Machine Interface (HMI), testing setups scripts (Labview/Python) and Supervisory Control and Data Acquisition (SCADA) systems for new or modified production lines
- Develop and implement robot programs (e.g., Epson and ABB) for various assembly tasks, including welding, Dispensing, material handling, and part insertion.
- Proficient in design, layout, and commissioning of new assembly lines and plant expansions.
- Manage the selection, procurement, installation, and validation of assembly equipment, fixtures, and tooling.
Project Management & Execution:
- Plan, execute, and monitor projects related to new model launches, capacity expansion, and process improvements from conception to completion.
- Develop project timelines, budgets, and resource allocation plans.
- Manage cross-functional teams, including production, quality, maintenance, and Quality function, to ensure project goals are met on time and within budget.
Design & Development:
- Configure and program industrial networking protocols (Ethernet/IP, Profinet, Modbus) for reliable communication between control devices, robots, and MES.
- Design, integrate, and configure industrial 2D and 3D vision systems (e.g., Cognex, Keyence, Sick) for critical quality checks, including weld inspection, presence/absence verification, error-proofing, and dimensional gauging.
- Develop, implement, and optimize assembly processes to improve quality, reduce cycle time, and minimize costs.
- Contribute in Developing work instructions, standard operating procedures (SOPs), and process flow diagrams.
- Proficient in contributing to the process documentation( PFD, PFMEA,CP and EFMEA) and PPAP knowledge.
- Utilize mechatronics principles for the design and implementation of automated and semi-automated assembly systems, robotics, and smart tooling.
- Develop and execute a preventive maintenance plan for all assembly equipment to maximize uptime and equipment longevity.
Continuous Improvement & Quality Assurance:
- Drive a culture of continuous improvement using methodologies such as Kaizen, Six Sigma, and 5S.
- Work closely with the Quality team to implement Poka-Yoke (mistake-proofing) and other quality control measures.
- Follow 8D approach, Analyze quality data, identify root causes of defects, and implement corrective and preventive actions (CAPA).
- Ensure all processes and equipment comply with safety, environmental, and quality standards (e.g., ISO 9001, TS 16949 and ISO45001).
Experience and Qualifications:
- Bachelor’s degree in Electrical, Mechatronics, Electronics or Mechanical Engineering.
- 7 to 10 years of relevant experience in manufacturing engineering within the automotive or two-wheeler industry. (Added weightage – If worked in the battery pack manufacturing environment)
Must have Competencies:
- Proven Experience in Battery assembly processes (i.e. Module assembly, Pack assembly,Cell placement, Spot welding, Laser Welding, Epoxy Dispensing, Tightening, AIS 156 norms and Automated inspection system).
- Exposure to the Latest Battery Pack Manufacturing process.
- Exposure to Greenfield working or Driving Brown field projects.
- Basic experience with PLC programming, Robotics, and Automation.
- Ability to manage multiple projects and priorities in a fast-paced environment.
- A proactive, results-oriented, and safety-conscious mindset.
- Having basic knowledge of concepts & programming language related to Artificial Intelligence (AI) and Machine Learning (ML) to optimize predictive maintenance, quality control, and process parameters
Apply : Job Description