Manager_ Battery Pack Testing and Design Verification

Manager_Battery Pack Testing and Design Verification

Function: Battery Engineering | Experience: 7+ years | Location: Hyderabad | Reports to: Vice President Battery Systems & Engineering

Role Overview

Lead HV Li-ion Battery Pack Testing, Validation & Design Verification, owning the complete verification cycle from DVP/DVP&R definition and test planning through execution, homologation, issue closure and SOP.

Mandatory: Demonstrated completion of at least one full battery pack program cycle from development through validation/SOP.

Key Responsibilities

• Own DVP/DVP&R and validation strategy from requirements definition through design verification, validation, homologation and SOP.
• Develop and execute test plans covering electrical, mechanical, thermal, environmental, durability, performance, abuse, safety and reliability.
• Define test methods, acceptance criteria, sequencing, samples, instrumentation and test schedules aligned with program milestones.
• Manage testing across internal labs, vehicle/system facilities and accredited external test agencies, including specialized regulatory and safety testing.
• Coordinate external testing for vibration/shock, EMC, environmental, IP/sealing, abuse/safety and homologation requirements.
• Own test readiness, execution, data analysis, reporting and requirement-to-test traceability.
• Lead test failure investigation and closure through root-cause analysis, corrective actions and re-validation with Pack, Cell, BMS, Thermal and Application Engineering teams.
• Drive battery homologation and compliance testing, including AIS-156, UN R100, UN 38.3 and applicable regional requirements.
• Establish test procedures, laboratory standards, HV safety protocols, instrumentation and data-management practices.
• Manage battery test infrastructure including battery cyclers, thermal chambers, DAQ, CAN/HV instrumentation and test automation.
• Drive test automation and digitalization to improve test throughput, repeatability, data quality and traceability.
• Lead validation reviews and provide clear program-level testing status, risks and escalation.
• Build and lead the Battery Testing & Design Verification team.

Required Qualifications & Experience

• Bachelor's/Master's degree in Electrical, Mechanical, Automotive, Electronics, Mechatronics or related engineering.
• 7+ years of hands-on experience in HV Li-ion battery pack testing, validation and design verification, preferably automotive/EV.
• Mandatory full-program experience: successfully delivered at least one battery pack program from development through validation/SOP.
• Strong expertise in DVP/DVP&R, validation planning, test execution, scheduling and test result evaluation.
• Proven experience managing external test agencies/accredited laboratories and specialized testing.
• Strong understanding of HV battery electrical, mechanical, thermal, environmental, durability and safety validation.
• Hands-on experience with battery cyclers, environmental chambers, DAQ, CAN tools, HV instrumentation and test systems.
• Strong knowledge of AIS-156, UN R100, UN 38.3 and relevant automotive battery homologation requirements.
• Strong root-cause and problem-solving skills using 8D, 5-Why, Fishbone and structured failure analysis.
• Greenfield battery testing lab setup/commissioning experience is a strong plus.

Leadership Profile

• Highly structured, data-driven and execution-oriented test leader.
• Strong ability to manage multiple test programs, external agencies and tight timelines.
• Excellent cross-functional communication and stakeholder management.
• Strong focus on test integrity, safety, repeatability, data quality and requirement compliance.
• Ability to challenge results, identify validation gaps and drive timely closure.

Key Success Outcomes

Robust DVP | On-time validation | Successful homologation | Zero critical test escapes | Rapid issue closure | High test-lab utilization | Reliable test data | SOP-ready battery packs

Preferred background: EV OEMs, battery manufacturers, Tier-1 automotive suppliers or testing organizations with strong experience in HV battery pack validation, design verification and automotive homologation.