Manufacturing Engineer - EV Battery Packs

About the role

Exponent Energy is hiring a Manufacturing Engineer in Bengaluru to join its Manufacturing Engineering team, which designs, stabilises and continuously improves production processes for EV battery packs and modules. The team builds reliable, scalable, automated and safe manufacturing systems that enable high-quality battery production at scale.

Key responsibilities

• Own process development, optimisation and support for EV battery module and pack assembly lines, working with Product, Quality, Automation, Maintenance and Supplier partners.
• Support day-to-day manufacturing operations and own critical processes such as laser welding, resistance welding, 1K and 2K dispensing, torque-controlled fastening, cell alignment and stacking, potting, insulation and sealing.
• Troubleshoot complex mechanical, electrical and process issues, perform root cause analysis (5-Why, Fish-bone, DOE) and implement CAPA.
• Support NPI, pilot builds, engineering trials and validation builds, and create and maintain SOPs, PFMEA, Control Plans, work instructions and process documentation.
• Evaluate manufacturability of new designs and give DFM/DFA feedback to design teams.
• Assist in installation, commissioning, FAT/SAT and capability studies of new equipment, and drive continuous improvement in cycle time, yield, quality and uptime.
• Program and optimise industrial robots (Mitsubishi/FANUC/KUKA or similar), configure EOAT and safety interlocks, troubleshoot PLC logic (Siemens, Allen Bradley, Mitsubishi), update HMIs and work with Profinet, Ethernet/IP, Modbus and OPC-UA.
• Contribute to the design of custom automation and fixtures, define requirements and acceptance criteria, and collaborate with machine suppliers on FAT, SAT and ramp-up.

Required profile

• Bachelor's degree in Mechanical, Mechatronics, Manufacturing or a related engineering field.
• 4-6 years of experience in EV battery pack/module manufacturing or high-precision automation.
• Experience supporting automated production lines and complex equipment, and hands-on experience in NPI, process validation and ramp-up.
• Familiarity with PFMEA, Control Plans and process documentation.
• Strong troubleshooting skills across mechanical, electrical and process domains, and strong communication and cross-functional collaboration skills.

Required skills

• Quality tools: 5-Why, Fishbone, DOE
• PLC programming and robot programming (Mitsubishi, FANUC, KUKA)
• Communication protocols: Profinet, Ethernet/IP, Modbus, OPC-UA