Senior Manager

Job Description : Senior Manager - Solar Cell Process

Position: Senior Manager - Solar Cell Process
Department: Cell Technology / Process Engineering
Reports To: Head - Cell Technology / Plant Head
Location: Narmadapuram , MP
Experience: 10-15 years, with 7+ years in solar cell manufacturing
Industry: Solar PV / Semiconductor / Advanced Manufacturing
Technology: TOPCon / N-Type; experience in PERC and/or HJT preferred
Role Purpose
Lead end-to-end solar cell process engineering and process optimization to achieve high cell efficiency, yield, quality, throughput, equipment utilization, and cost competitiveness.
The incumbent will own process stability and continuous improvement across the wafer-to-cell manufacturing flow, lead process development and technology transfer, support new line commissioning and ramp-up, and build a strong process engineering team.

Key Responsibilities

1. Solar Cell Process Ownership

• Own and optimize end-to-end cell manufacturing processes, including:

• Wafer incoming & cleaning

• Texturing

• Diffusion / emitter formation

• Oxidation / annealing

• LPCVD / PECVD

• Wet chemical processes

• Laser processes

• Metallization / screen printing

• Firing / curing

• Testing, EL inspection and sorting

• Develop and maintain process recipes, specifications, SOPs, work instructions and process control plans.

• Ensure process capability, stability and repeatability during mass production.

• Establish and monitor CTQs and critical process parameters for each process step.

2. Yield & Cell Efficiency Improvement

• Drive continuous improvement of cell efficiency, yield, throughput and process capability.
• Analyze electrical, optical and process data to identify loss mechanisms.
• Lead structured RCA for efficiency loss, yield loss, defects and process excursions.
• Develop and execute DOE, experiments and process optimization programs.
• Reduce scrap, rework, breakage and wafer losses.
• Drive improvement in Voc, Jsc, FF and overall cell efficiency.

3. TOPCon / N-Type Technology

• Strong ownership of N-type/TOPCon process integration and optimization.

• Optimize critical parameters related to:

• Surface texturing

• Diffusion

• Tunnel oxide formation

• Poly-Si deposition/doping

• Passivation

• Metallization

• Contact resistance

• Firing/thermal budget

• Support technology upgrades and transition toward higher-efficiency cell architectures.

• Benchmark processes, materials and equipment against industry best practices.

4. Process Control & Quality

• Implement SPC, FMEA, Control Plans, Cp/Cpk, MSA and process capability monitoring.
• Establish reaction plans for process deviations and out-of-control conditions.
• Work closely with Quality to reduce defect rates and improve customer quality.
• Lead CAPA and preventive-action programs.
• Develop and maintain Manufacturing Quality Plans (MQP) and process documentation.

5. New Line / Greenfield Commissioning

• Support technology selection, equipment specifications and process-flow development.
• Lead process qualification, equipment buy-off and production readiness.
• Coordinate with OEMs during installation, commissioning and ramp-up.
• Develop recipes, SOPs and process standards for new equipment.
• Lead process stabilization from pilot production through mass production.
• Support technology transfer and successful production ramp-up.

6. Productivity & Cost Optimization

• Improve throughput, cycle time and line capacity.

• Drive reduction in:

• Cost per wafer

• Cost per cell

• Chemical consumption

• Gas consumption

• Paste consumption

• Consumable cost

• Scrap and breakage

• Identify bottlenecks and execute debottlenecking projects.

• Improve OEE through close coordination with Production, Maintenance and Equipment Engineering.

7. Data Analytics & Problem Solving

• Establish robust process-data monitoring and statistical analysis.
• Use tools such as JMP / Minitab / Excel / statistical analytics platforms for process optimization.
• Develop dashboards for yield, efficiency, defect Pareto and process capability.
• Use 8D, DMAIC, RCA, Fishbone, 5-Why and other structured problem-solving methodologies.

8. Team Leadership

• Lead and mentor Process Engineers, Senior Engineers and technical specialists.
• Define team objectives, KPIs and development plans.
• Build technical competency in solar cell process engineering.
• Conduct technical reviews and ensure effective shift/process support.
• Develop a culture of data-driven decision making and continuous improvement.

9. Cross-Functional Collaboration
Work closely with:

• Production / Operations
• Equipment Engineering
• Maintenance
• Quality
• R&D / Cell Technology
• Materials / Procurement
• Planning
• EHS
• Automation / Digital teams
• Equipment and material suppliers

Key Performance Indicators

• Cell Conversion Efficiency (%)
• Average Cell Efficiency / Efficiency Distribution
• Cell Yield (%)
• First Pass Yield (FPY)
• OEE (%)
• Throughput / UPH
• Line Capacity Utilization
• Process Capability Cp/Cpk
• Defect PPM
• Wafer Breakage %
• Scrap %
• Chemical / Gas / Paste Consumption
• Cost per Watt
• Process Downtime
• Customer Quality / Reliability
• Number and impact of CI projects

Education
Essential:

• B.E./B.Tech in Electronics, Electrical, Chemical, Materials, Metallurgy, Mechanical, Production or related engineering discipline.

Preferred:

• M.Tech / M.E. in Materials Science, Semiconductor Technology, Electronics, Chemical Engineering or related field.
• Six Sigma Green Belt/Black Belt certification preferred.

Experience

• 10-15 years total experience in manufacturing/process engineering.
• 7+ years preferably in solar cell manufacturing, semiconductor or similar high-volume advanced manufacturing.
• Strong hands-on experience in TOPCon / N-type solar cell technology.
• Experience in PERC and/or HJT will be an advantage.
• Greenfield plant commissioning and production ramp-up experience strongly preferred.

Technical Skills

• TOPCon / N-type solar cell process
• PERC / HJT fundamentals
• Diffusion
• LPCVD / PECVD
• Wet chemical processing
• Texturing
• Annealing / thermal processes
• Metallization and firing
• Laser processing
• EL / IV characterization
• SPC / DOE / FMEA
• Six Sigma / Lean Manufacturing
• RCA / CAPA / 8D
• Process capability analysis
• Yield engineering
• Equipment qualification
• Process validation
• Manufacturing automation and data analytics

Leadership Competencies

• Strong technical and analytical capability
• Strategic and hands-on problem solving
• Strong ownership and accountability
• Cross-functional leadership
• Decision-making under production pressure
• Team building and mentoring
• Excellent communication and stakeholder management
• Continuous-improvement mindset
• Ability to work in a high-volume, 247 manufacturing environment