Battery System Assembly Operator Course
The Battery System Assembly Operator Course provides hands-on training to assemble, test, and maintain electric vehicle battery packs safely and efficiently. Learners gain practical skills in handling high-voltage components, connecting cells and modules, performing quality checks, and following industry-standard safety protocols. This course equips students and technicians with the expertise needed to work confidently in EV manufacturing plants, workshops, and service centers, building a strong foundation for a career in the rapidly growing electric mobility sector.
- 450 Hours (2 hours/day x 6 days/week x 38 weeks) OR at your own pace
- Hindi, English
- Learn & Get Certified
- Basic & Intermediate
- Hands-On Training
Online Course Fees
Offline Course Fees
About this course
The Battery System Assembly Operator Course is a 72-hour hands-on training program.
It is designed to prepare learners for entry-level roles in battery pack assembly, focusing on safe handling, assembly techniques, cell preparation, and quality control procedures used in EV battery manufacturing units, energy storage companies, and electronics production facilities.
Through structured modules, participants learn:
– Basics of battery types: Li-ion, LFP, NMC, cylindrical, pouch, prismatic cells
– Cell sorting, grading, and preparation for assembly
– Series–parallel configuration, busbar installation, and cell alignment
– Spot welding, soldering, and connection techniques
– Insulation methods, padding, and enclosure assembly
– Introduction to Battery Management System (BMS) components and wiring
– Use of assembly tools: welders, crimpers, torque tools, testing jigs
– Quality checks: voltage testing, cell balancing checks, insulation testing
– Common assembly errors and preventive measures
– Safety guidelines for handling cells, thermal protection, and storage compliance
Hands-on sessions include cell preparation, spot welding practice, busbar assembly, BMS wiring exercises, thermal pad placement, pack enclosure fitting, and basic electrical testing to ensure proper assembly.
By the end of the program, participants are prepared to:
– assemble battery modules and packs following industry SOPs,
– perform basic testing and quality checks during production, and
– work as Battery Assembly Operators, Production Line Technicians, or EV Battery Assembly Assistants in battery manufacturing and EV industries.
- Online Course Fees: ₹3500, ₹2500 (incl. GST) (Excluding tools & equipment cost)
- Offline Course Fees: ₹18500, ₹17000 (incl. GST) (Excluding tools & equipment cost)
- Certification: ESSCI
- Duration: 450 Hours (2 hours/day x 6 days/week x 38 weeks) OR at your own pace
What you'll learn
After this course you will learn:
- Battery Basics: Understand different battery types, components, and their role in electric vehicles.
- Cell-to-Pack Assembly: Learn how to assemble individual cells into modules and complete battery packs.
- High-Voltage Safety Protocols: Gain skills in safely handling high-voltage components and preventing short circuits.
- Use of Assembly Tools: Hands-on training with tools and equipment used in EV battery assembly.
- Quality Checks and Testing: Inspect and test battery packs for defects, performance, and safety compliance.
- Module Integration: Connect modules, wiring harnesses, and protective components correctly for functional battery packs.
- Thermal and Mechanical Considerations: Learn techniques for insulation, cooling, and vibration-proofing in battery assembly.
- Industry Standards and Best Practices: Follow standard operating procedures and quality guidelines used in EV manufacturing.
Course Content
Why take this course?
This course provides hands-on training to assemble and integrate battery packs and systems used in electric vehicles, renewable energy storage, and industrial applications. You will learn about cell handling, module assembly, wiring, safety protocols, and quality testing to ensure reliable and efficient battery systems. As demand for EVs and energy storage solutions grows, skilled assembly operators are crucial for manufacturing high-performance, safe battery systems. This course equips you with practical, job-ready skills for a career in the rapidly expanding battery and clean energy industry.
How to use online TCoE platform?
Tools and Equipment required
National Skill Development Mission
Module 1: Introduction and orientation to the role of a Battery System
- Describe the role and responsibilities of a Battery System Assembly Operator
Module 2: Assembly of the Battery system as per design
- Explain the design and connectivity requirement between various components of the assembly.
- Explain the criteria for selecting Battery system components and functional blocks.
- Describe the process of planning the assembly as per quality, industry and compliance standards.
- Explain the precautionary measures to be taken before starting the assembly.
- Demonstrate the process of assembling various components of the battery.
Module 3: Testing the Battery system after assembly
- Explain the globally accepted regulatory standards to be followed during testing.
- Demonstrate the process of testing the battery cells and modules for various performance parameters.
- Explain how to find the cause of the problem if the test results diverge from specifications.
- Demonstrate the use of relevant techniques to rectify malfunctions as per the SOP.
Module 4: Soft Skills and Work Ethics
- Work effectively at the workplace.
- Demonstrate practices related to gender and PwD sensitization.
Module 5: Basic Health and Safety Practice
- Apply health and safety practices at the workplace
Module 6: Employability Skills
- Discuss about Employability Skills in meeting the job requirements.
- Describe opportunities as an entrepreneur.
- Describe ways of preparing for apprenticeship & Jobs appropriately.
Module 7: On-the-Job Training
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Battery Pack Assembly and Safety Procedures
This topic focuses on the step-by-step process of assembling battery packs used in electric vehicles — from arranging individual cells and connecting modules to integrating wiring harnesses and protective components. Learners will gain hands-on knowledge of assembly tools, joining techniques, insulation methods, and testing procedures. Special emphasis is given to safety protocols, including handling high-voltage components, preventing short circuits, and ensuring quality control during assembly. Mastering this topic prepares learners to work confidently and safely in EV battery manufacturing and maintenance environments.
Job Opportunities
Here are some interesting job opportunities after completing the Battery System Assembly Operator course:
Battery Assembly Technician – Assemble and test EV battery packs in manufacturing plants, ensuring proper connections and quality standards.
High-Voltage Battery Operator – Work with high-voltage cells and modules, following safety protocols for installation and maintenance.
Battery Testing and Quality Inspector – Inspect assembled battery packs for defects, perform functional tests, and ensure compliance with safety and performance standards.
EV Manufacturing Operator – Operate machinery and tools used in the production and assembly of battery systems for electric vehicles.
Battery Pack Maintenance Technician – Diagnose, repair, and replace faulty modules in battery packs used in EV fleets or service centers.
Assembly Line Supervisor (Battery Systems) – Oversee assembly operations, ensure safety compliance, and maintain workflow efficiency in battery manufacturing units.
EV Workshop Technician – Provide hands-on support in assembling or replacing battery packs in service centers for electric vehicles.
- Trainer / Instructor – Teach practical battery assembly skills to new operators and technicians entering the EV sector.
Frequently asked questions
What is the Battery System Assembly Operator course about?
This course trains learners to assemble, test, and maintain electric vehicle battery packs safely and efficiently, covering practical skills, tools, and safety procedures required in EV battery manufacturing.
Who should take this course?
The course is ideal for technicians, workshop staff, vocational students, and anyone interested in hands-on EV battery assembly and maintenance roles.
Do I need prior experience with batteries or EVs?
No prior experience is necessary. The course starts with basic concepts and gradually moves to advanced assembly techniques and safety practices.
What practical skills will I gain?
You’ll learn how to assemble battery cells into modules and packs, connect wiring harnesses, perform insulation, conduct basic testing, and follow high-voltage safety protocols.
Will this course help me get a job in the EV industry?
Yes! With the EV market growing rapidly, skilled battery assembly operators are in high demand in manufacturing plants, service centers, and EV workshops.
What safety measures will I learn?
The course emphasizes handling high-voltage components safely, preventing short circuits, using protective equipment, and following industry-standard safety procedures.
