Job Description – Assistant Manager – Pre-Dispatch Inspection (PDI) – BESS
Position: Assistant Manager – Pre-Dispatch Inspection (PDI) – Battery Energy Storage Systems (BESS)
Department: Quality Assurance
Location: Chennai / Oragadam
Reports To: Manager – Quality / Head – Quality
Role Summary
The Assistant Manager – PDI is responsible for leading the Pre-Dispatch Inspection (PDI) function for Battery Energy Storage Systems (BESS), ensuring that every battery module, pack, rack, container, and integrated system meets customer specifications, internal quality standards, and applicable international regulations before shipment. The role oversees final inspection, functional testing, documentation review, and dispatch readiness while coordinating with Production, Engineering, Testing, Supply Chain, and Logistics to achieve defect-free and on-time deliveries.
Key Responsibilities 1. Lead Pre-Dispatch Inspection Activities
- Plan and manage daily PDI activities for complete BESS systems.
- Ensure timely inspection of products as per production and dispatch schedules.
- Allocate inspection activities among team members.
- Ensure compliance with approved inspection plans and quality procedures.
2. Final Product Inspection
Lead final inspection of:
- Battery Cells (where applicable)
- Battery Modules
- Battery Packs (LV/HV)
- Battery Racks
- BMS Integration
- Power Conversion System (PCS)
- Energy Management System (EMS)
- HVAC System
- Fire Detection & Suppression System
- Container Integration
- Auxiliary Systems
Verify:
- Mechanical assembly quality
- Electrical installation
- Component traceability
- Workmanship
- Labeling and product identification
- Safety compliance
3. Electrical & Functional Verification
Ensure completion and review of:
- Insulation Resistance (IR) Tests
- High Voltage (Hi-Pot) Tests
- Ground Continuity Tests
- Torque Verification
- Polarity Checks
- Communication Tests (CAN, Modbus, Ethernet)
- BMS Functional Verification
- PCS Functional Tests
- EMS Communication Validation
- Charge/Discharge Simulation
- SOC/SOH Verification
- Emergency Stop (E-Stop) Validation
- Alarm & Interlock Verification
- HVAC Performance Checks
- Fire Suppression System Functional Checks
4. Documentation Review
Verify completeness and accuracy of:
- Factory Acceptance Test (FAT) Reports
- PDI Checklists
- Electrical Test Reports
- Calibration Certificates
- Inspection Records
- As-Built Drawings
- Operation & Maintenance Manuals
- Warranty Documents
- Packing Lists
- Customer Inspection Reports
- Product Traceability Records
5. Customer Inspection & FAT Support
- Coordinate customer and third-party inspections.
- Lead Factory Acceptance Tests (FAT).
- Address customer observations and quality concerns.
- Ensure timely closure of inspection punch points.
- Obtain customer dispatch approval.
6. Non-Conformance Management
- Raise Non-Conformance Reports (NCRs).
- Conduct root cause analysis using 5 Why, Fishbone Diagram, and 8D methodology.
- Coordinate corrective and preventive actions (CAPA).
- Verify effectiveness of corrective actions before dispatch.
7. Dispatch Readiness
Ensure products are ready for shipment by verifying:
- Packaging quality
- Export compliance
- Shock and tilt indicators
- Moisture protection
- Container cleanliness
- Product labeling
- Shipping documentation
- Customer-specific dispatch requirements
8. Team Management
- Lead and mentor PDI engineers and inspectors.
- Conduct skill development and training sessions.
- Monitor team productivity and inspection quality.
- Ensure adherence to EHS and quality practices.
9. Cross-Functional Coordination
Work closely with:
- Production
- Manufacturing Engineering
- Process Engineering
- Testing & Validation
- Quality Assurance
- Supply Chain
- Stores
- Logistics
- Project Management
- Service Team
to ensure seamless product release.
10. Continuous Improvement
- Reduce dispatch defects and customer complaints.
- Improve First Pass Yield (FPY).
- Enhance inspection efficiency through digital checklists and standardization.
- Drive Lean Manufacturing, Kaizen, and Six Sigma initiatives.
- Analyze quality trends and implement preventive actions.
Education
- B.E./B.Tech in Electrical, Electronics, Mechanical, Mechatronics, Instrumentation, or related Engineering discipline.
Experience
- 6–10 years of experience in Quality, Final Inspection, PDI, FAT, or Manufacturing Quality.
- Minimum 3 years in Battery Energy Storage Systems (BESS), EV Battery Manufacturing, Lithium-ion Battery Packs, Renewable Energy, Power Electronics, or Electrical Equipment Manufacturing.
- Experience with containerized BESS is highly preferred.
Technical Skills
- Battery Pack & Rack Inspection
- BMS Architecture
- PCS & EMS Integration
- High Voltage Safety
- Electrical Testing (IR, Hi-Pot, Ground Continuity)
- Functional Testing & FAT
- Reading Electrical Schematics and GA Drawings
- Quality Management Systems (QMS)
- NCR & CAPA Management
- Root Cause Analysis (8D, 5 Why, Fishbone)
- PFMEA & Control Plans
- SAP/ERP Systems
- MS Office
Knowledge of Standards
- IEC 62619
- IEC 62933
- IEC 62477
- UL 9540
- UL 1973
- ISO 9001
- ISO 14001
- ISO 45001
- Relevant customer and utility specifications
Key Competencies
- Leadership and Team Management
- Strong Analytical & Problem-Solving Skills
- Attention to Detail
- Decision-Making
- Customer Focus
- Effective Communication
- Cross-Functional Collaboration
- Planning & Organizing
- Quality Mindset
- Continuous Improvement Orientation
Key Performance Indicators (KPIs)
- On-Time PDI Completion (%)
- First Pass Dispatch Approval Rate
- Customer Acceptance Rate During FAT
- Dispatch-Related Customer Complaints
- Warranty Claims Due to Manufacturing Defects
- Number of NCRs Raised and Closed
- CAPA Closure Effectiveness
- Documentation Accuracy
- Rework Reduction
- Inspection Productivity
- First Pass Yield (FPY)
- On-Time Dispatch Performance
Day-to-Day Activities
- Review daily production and dispatch plans.
- Allocate inspection tasks to the PDI team.
- Conduct final inspections and witness functional tests.
- Review test reports and quality documentation.
- Lead customer FATs and third-party inspections.
- Coordinate defect resolution with Production and Engineering.
- Approve completed BESS units for dispatch.
- Monitor quality KPIs and prepare daily/weekly inspection reports.
- Conduct team meetings, training, and continuous improvement reviews.
- Ensure compliance with safety, quality, and regulatory requirements throughout the dispatch process.
