Senior EHS Manager - Battery Manufacturing

Job Title : Senior EHS Manager - Battery Manufacturing

Location : GMR Plant, Hyderabad.

Reports To : Production Head

Position Summary

Own the site’s EHS strategy and execution for lithium‑ion manufacturing operations (cell, module, pack). Deliver zero harm and zero fires through robust risk assessment, process safety, hazardous‑chemical and HF exposure control, HV electrical safety, contractor management, emergency preparedness, legal compliance, and a strong safety culture from incoming to dispatch .

Key Responsibilities

Risk Assessment & Process Safety

• Establish and maintain HIRA / JSA for all operations : slurry mixing, coating & drying, solvent recovery, formation & aging, electrolyte filling, laser / ultrasonic welding, module / pack assembly, repair bays, and test labs (charge / discharge).
• Facilitate HAZOP / What‑If / Bow‑Tie for high‑risk units; define Safe Operating Limits (SOLs) , interlocks, and critical alarms.
• Drive MOC (Management of Change) and PSSR before commissioning / start‑ups, changeovers, or new chemicals / equipment.
• Implement plant‑wide ESD control (earthing, ionizers, footwear / floor resistance audits) for cell and electronics areas.

Chemical Safety & Industrial Hygiene

• Govern safe lifecycle management of electrolyte salts / solvents (e.g., LPF in EC / EMC / DEC), cathode / anode powders, and cleaning agents.
• Run chemical approval workflows, SDS control, segregated storage, spill kits, LEL / VOC monitoring (NMP where applicable), and LEV / ventilation checks.
• Deploy HF exposure control plans (detectors, neutralization kits, calcium‑gluconate protocols); define PPE matrices and IH sampling; maintain medical surveillance as required.

High‑Voltage (HV) & Electrical Safety

• Define and enforce HV safety for assembly, testing, maintenance, and repair (IR / Hi‑Pot, cyclers, contactor testing).
• Set arc‑flash boundaries , insulated‑tool requirements, fail‑safe interlocks, E‑stops , and strict LOTO ; train / qualify Authorized / Competent Persons.

Fire Protection & Thermal‑Runaway Readiness

• Conduct fire risk assessments for cell storage, formation rooms, and pack lines ; maintain appropriate detection / suppression (e.g., VESDA, gas detection, sprinklers / water‑mist / clean agent as engineered).
• Author thermal‑runaway response SOPs , quarantine / immersion or sand / vermiculite containment protocols, and post‑event cleanup (including HF neutralization).
• Run periodic battery fire & electrolyte spill drills ; coordinate with local fire services and mutual‑aid partners.

Machinery & Facility Safety

• Ensure machine guarding , light curtains, interlocks, and robot / AMR safety on automated lines; validate with risk assessments.
• Operate robust Permit‑to‑Work controls (hot work, confined space, work at height, energized work); verify lifting plans and certifications.
• Ensure compliance for pressure vessels, boilers, DG sets, compressed gases , and electrical installations.

Contractor & Construction Safety

• Implement Contractor Safety Management : pre‑qualification, onboarding, toolbox talks, JSAs, supervision ratios, and performance scorecards.
• Enforce barricading, PTW, rigging / lifting controls during shutdowns, brownfield / greenfield modifications, and utility work.

Environmental & Waste (EHS Interface)

• Govern hazardous waste handling (black mass, electrolyte residues, contaminated PPE / filters), labeling, manifesting, and authorized disposal / recycling.
• Monitor air emissions , VOC / NMP controls (if used), wastewater / ETP‑STP , and secondary containment .
• Maintain a Legal & Compliance Register and on‑time submissions to statutory bodies (State PCB / Factory Inspectorate).

Training, Culture & Communication

• Run site‑wide training on Li‑ion fundamentals, chemical hygiene, HF first aid, HV awareness, LOTO, ergonomics, emergency response ; certify fire wardens & first responders .
• Drive Behavior‑Based Safety (BBS) , safety observations, and near‑miss programs with high participation and timely closure.

Incident Investigation & Performance Management

• Lead investigations using 5‑Why, 8D, TapRooT (or equivalent) ; ensure CAPA effectiveness and recurrence prevention.
• Publish weekly / monthly dashboards on leading & lagging indicators (TRIR, LTIFR, near‑miss, SIF potential, audit scores, training coverage).

Audits, Systems & Certifications

• Plan and conduct internal audits ; host external (customer / third‑party / statutory) audits.
• Maintain and improve ISO 45001 ; support ISO 14001 / 9001 integration; control documentation and management reviews.

Qualifications

• B.E. / B.Tech with ADIS / PG Diploma in Industrial Safety (mandatory); NEBOSH / IOSH , ISO 45001 Lead Auditor preferred.
• 9–15+ years total EHS experience with at least 3–5+ years in Li‑ion / chemical process or closely related manufacturing.
• Proven leadership in audits / statutory liaison, contractor safety, process safety, and emergency management.

Key Skills & Competencies

• HIRA / JSA, HAZOP, MOC, PSSR, LOTO, PTW
• Chemical hygiene (electrolytes / solvents), HF risk control, IH sampling & exposure assessments
• HV & arc‑flash fundamentals, battery test‑lab safety
• Fire protection (detection / suppression zoning, alarm logic), emergency response & crisis management
• ISO 45001 / ISO 14001 management systems
• Data analysis & EHS dashboards (Excel / Power BI); incident investigation tools

Key Competencies

• Strong technical depth in both mechanical and electrical domains.
• Ability to lead and mentor design engineers.
• Analytical mindset with attention to detail.