Manager -PDI

Role Summary

The PDI Engineer is responsible for conducting final inspection, testing, documentation verification, and dispatch clearance of Battery Energy Storage Systems (BESS) before shipment to customers. The role ensures every BESS container, rack, pack, and associated systems meet customer specifications, quality standards, regulatory requirements, and internal acceptance criteria prior to dispatch. The objective is to eliminate field failures, reduce warranty claims, and ensure first-time-right deliveries. Pre-dispatch inspection verifies product quality, functionality, documentation, and customer-specific requirements before shipment.

Key Responsibilities 1. Final Product Inspection

• Perform comprehensive Pre-Dispatch Inspection (PDI) of complete BESS systems.
• Verify assembly quality of:
  • Battery Modules
  • Battery Packs
  • Battery Racks
  • BESS Container
  • PCS integration
  • EMS interface
  • HVAC
  • Fire Suppression System
  • Auxiliary Systems
• Inspect workmanship, labeling, identification, and product appearance.

2. Electrical Inspection

• Verify HV/LV wiring.
• Check cable routing.
• Inspect busbar installation.
• Verify torque values.
• Conduct insulation resistance tests.
• Verify grounding continuity.
• Check polarity.
• Perform dielectric withstand tests where applicable.

3. Functional Testing

Conduct final operational testing including:

• BMS functionality
• Cell balancing
• Rack communication
• PCS communication
• EMS communication
• SOC verification
• Charge/Discharge operation
• Alarm verification
• Emergency Stop (E-Stop)
• Smoke detection
• Fire suppression system
• HVAC operation
• Door interlocks
• HMI verification

4. Mechanical Inspection

• Verify enclosure integrity.
• Check weld quality.
• Inspect mounting hardware.
• Verify torque compliance.
• Ensure no transit damage.
• Check IP sealing.
• Verify door alignment.
• Inspect cooling duct installation.
• Ensure proper cable gland installation.

5. Documentation Verification

Ensure dispatch package includes:

• FAT Report
• Test Reports
• Inspection Reports
• Customer Checklists
• Electrical Drawings
• GA Drawings
• As-built Drawings
• Operation Manual
• Maintenance Manual
• Warranty Documents
• Serial Number Traceability
• Calibration Certificates

6. Dispatch Readiness

• Approve product for shipment.
• Coordinate with Logistics.
• Verify packing quality.
• Ensure shock indicators are installed.
• Verify moisture protection.
• Ensure export packaging requirements are met.
• Confirm customer-specific packaging standards.

7. Quality Documentation

• Maintain PDI checklists.
• Record inspection observations.
• Raise NCRs.
• Generate punch lists.
• Track closure of defects.
• Maintain dispatch approval records.

8. Customer Compliance

Ensure product complies with:

• Customer specifications
• Internal Quality Standards
• IEC Standards
• UL Standards
• CE Requirements
• Safety Regulations
• Contractual requirements

9. Defect Management

• Identify defects before dispatch.
• Coordinate with Production for rectification.
• Verify corrective actions.
• Re-inspect after rework.
• Approve only conforming products.

10. Continuous Improvement

• Analyze recurring dispatch defects.
• Reduce customer complaints.
• Improve First Pass Yield (FPY).
• Recommend improvements in manufacturing processes.
• Support CAPA implementation.
• Participate in quality improvement initiatives.

Qualifications

• B.E./B.Tech in Electrical, Electronics, Mechanical, Mechatronics, or Instrumentation Engineering.