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.
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
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.
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.
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
HVAC operation
Door interlocks
HMI verification
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Recommend improvements in manufacturing processes.
Support CAPA implementation.
Participate in quality improvement initiatives.
B.E./B.Tech in Electrical, Electronics, Mechanical, Mechatronics, or Instrumentation Engineering.
3–8 years in: BESS Manufacturing Battery Pack Assembly Electrical Panel Manufacturing Renewable Energy Power Electronics EV Battery Manufacturing Industrial Electrical Systems
BESS Manufacturing
Battery Pack Assembly
Electrical Panel Manufacturing
Renewable Energy
Power Electronics
EV Battery Manufacturing
Industrial Electrical Systems
Experience in PDI, FAT, or final inspection is preferred.
Battery Pack Inspection
BMS Fundamentals
HV Safety
Electrical Testing
FAT Procedures
PDI Checklists
Root Cause Analysis
NCR Management
Reading Electrical Drawings
Torque Audits
Continuity Testing
Insulation Resistance Testing
Communication Protocols (CAN, Modbus)
Quality Documentation
MS Office
ERP/SAP
IEC 62619
IEC 62933
IEC 62477
UL 9540
UL 1973
ISO 9001
ISO 14001
ISO 45001
Attention to Detail
Problem Solving
Quality Mindset
Analytical Skills
Communication Skills
Cross-functional Coordination
Documentation Excellence
Decision Making
Customer Focus
Safety Awareness
First Pass Dispatch Approval (%)
PDI Defect Detection Rate
Customer Complaints after Dispatch
Warranty Claims
Dispatch On-Time Clearance
FAT Pass Rate
Documentation Accuracy
Rework Reduction
Dispatch Quality Score
CAPA Closure Effectiveness
Review daily dispatch schedule.
Perform final inspection of completed BESS units.
Execute electrical and functional verification tests.
Complete PDI checklists and quality documentation.
Coordinate with Production to resolve identified defects.
Verify implementation of corrective actions and re-inspect repaired units.
Approve conforming systems for dispatch and issue quality clearance.
Support customer Factory Acceptance Tests (FAT) when required.
Track inspection metrics and recurring quality issues.
Participate in daily quality review and continuous improvement meetings.
Position: Assistant Manager – Pre-Dispatch Inspection (PDI) – Battery Energy Storage Systems (BESS)
Department: Quality Assurance
Location
Chennai / Oragadam
Reports To: Manager – Quality / Head – Quality
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.
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.
Lead final inspection of:
Battery Cells (where applicable)
Battery Packs (LV/HV)
BMS Integration
Power Conversion System (PCS)
Energy Management System (EMS)
HVAC System
Fire Detection & Suppression System
Container Integration
Verify:
Mechanical assembly quality
Electrical installation
Component traceability
Workmanship
Labeling and product identification
Safety compliance
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
Verify completeness and accuracy of:
Factory Acceptance Test (FAT) Reports
Electrical Test Reports
Inspection Records
Operation & Maintenance Manuals
Packing Lists
Customer Inspection Reports
Product Traceability Records
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.
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.
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
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.
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.
Reduce dispatch defects and customer complaints.
Enhance inspection efficiency through digital checklists and standardization.
Drive Lean Manufacturing, Kaizen, and Six Sigma initiatives.
Analyze quality trends and implement preventive actions.
B.E./B.Tech in Electrical, Electronics, Mechanical, Mechatronics, Instrumentation, or related Engineering discipline.
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.
