Manoj Kumar C

Electrode Fabrication & Process Optimization:

• Optimized slurry mixing parameters (solid loading, binder ratio, CNT dispersion, blade RPM) improved batch reproducibility and reduced viscosity variation by 20%, enhancing process capability and scale-up stability.
• Conducted DOE studies to refine binder systems (PVDF, VDF, CMC/SBR, PAA) and to improve dispersion of conductive additives, improving electrode uniformity and reproducibility.
• Led stabilization of Dürr slot-die coating process through rheology control and parameter window optimization (viscosity, flow rate, tension, web speed), achieving +/- 3% thickness uniformity and reducing coating rejection from 12% to 4%.
• Engineered calendering process parameters (roll pressure, gap, tension, temperature) for 4680 electrodes, achieving +/- 0.005 g/cc density control and a 15 to 20% increase in peel strength, directly reducing winding-induced defects.
• Directed cross-functional pilot-to-giga transition for 4680 cylindrical cell electrodes, aligning R&D and winding teams to industrialize high-loading architectures with enhanced process capability and mass-product

Process Improvement & Quality Control:

• Managed electrode fabrication and cell assembly operations in controlled dry-room environments (
• Led cross-functional quality and yield optimization programs leveraging DOE, SPC, Cp/Cpk, FMEA risk assessment, structured RCA (5-Why, Fishbone), OEE analysis, and CAPA deployment, achieving 10% yield improvement, 30% defect reduction, and enhanced process capability (>1.4 Cpk) in electrode manufacturing.

Scaling & Collaboration:

• Collaborated with cross-functional teams and equipment vendors to commission new machinery and automate production lines, resolving bottlenecks to support the transition from pilot scale to mass production.
• Conducted rigorous battery performance evaluations, including C-rate testing and coulombic efficiency analysis, to validate process improvements and material changes.
• Trained and supported new team members, maintaining culture of collaboration.