New RESS Battery Assembly Line: Installation, Debug & PPAP


Oversee completion of the install, debug, and PPAP of a new RESS battery line for one of the largest automotive OEMs in North America. This required stepping in mid-project to redirect client team, providing a clear path to a successful launch.



Achieved Start of Regular Production (SORP) per schedule; satisfied safety requirements and fostered positive teamwork.


  • Lack of clear direction in meeting launch requirements and existing workforce with limited RESS assembly/manufacturing experience.
  • Facilitated daily collaboration via formal and informal meetings with all parties: Operations, Maintenance, OEM, and Contractors.
  • Ensured that BOP (Bill of Process), PFMEA (Process Failure Mode Effects Analysis), PFCM (Plant Floor Change Management), and Error Proofing processes were properly followed.
  • Consistently tracked progress and developed countermeasures where required.
  • Managed qualification (MRO and PPAP) and launch of assembly equipment into production.
  • Co-managed on-going CI (Continuous Improvement) after SORP to improve JPH (Jobs Per Hour) and line efficiency.
  • Safety: Proper care was critical in processing the battery through the assembly line without endangering those exposed to high risk factors. Ongoing safety training and reminders were crucial to prevent accidents.
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