Role DescriptionForm Energy is hiring a Lead (Staff) Process Engineer to join our Operations Engineering team to help ramp production of our iron-air battery. In this role, you will drive the optimization of critical production workflows, using data-driven insights to enhance quality, throughput, and yield. You will collaborate with leaders across the organization to bridge the gap between process development and high-volume execution, ensuring our manufacturing processes are both robust and scalable. By managing these technical improvements, you will directly enable the reliable delivery of long-duration energy storage systems essential for a stable electric grid.
What you'll do:- Lead continuous improvements to optimize production processes, reduce costs, improve quality, and increase efficiency
- Drive collaboration with cross-functional teams to identify and solve production issues, while maintaining rigorous product quality standards
- Conduct advanced root cause analysis and develop comprehensive corrective and preventive actions to improve large-scale equipment, processes, and systems.
- Establish and analyze sophisticated key performance indicators to identify strategic areas for improvement and ensure high-level production targets are met or exceeded.
- Ensure organizational compliance with all safety regulations and company policies related to environmental, health, and safety.
- Drive the optimized usage of PLM, MES, and ERP systems to enhance manufacturing intelligence and sustainability tracking.
- Support factory layout and optimization efforts, capacity planning, scalability plans, crew cycling, tool cycling, etc.
What you'll bring:- 7+ years of experience in a fast-paced manufacturing or production development environment and a Bachelor's degree in Chemical Engineering, Mechanical engineering, or equivalent
- Demonstrated mastery in owning manufacturing processes and showing accountability for their quality, throughput, yield, and overall success
- Advanced proficiency using statistical methods for making process development decisions (using JMP or Minitab or equivalent), with a high level of proficiency on SQL data query.
- Extensive experience leading multidisciplinary projects and mentoring engineering teams in process improvement and industrial best practices.
- Deep technical expertise in creating DFMEAs and PFMEAs and implementing robust controls for system-wide risk mitigation.
- Pragmatic problem-solving skills and a history of thriving on complexity within a high-growth manufacturing environment.
- Intellectual curiosity and a drive for continuous learning to solve the unique challenges of long-duration energy storage.
Where you'll work:This role is based at Form Factory 1 in Weirton, WV-an easy commute from the city of Pittsburgh, PA. This 550,000-square-foot facility is our hub for high-volume battery production and a leader in the new era of American energy manufacturing. Relocation assistance is available.
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Humanity is a cornerstone of Form Energy's culture, and we make sure our compensation and benefits reflect that. Form Energy offers competitive salaries, stock options, and a holistic benefits package to ensure all employees have what they need to thrive while working here.
When it comes to you and your family's health, we cover 100% of medical, dental, and vision premiums for full-time employees - and 80% of healthcare premiums for dependents. This starts from day one. We also offer at least 12 weeks of paid leave for new parents (up to 20 weeks for birthing parents), and generous vacation policies to give employees time to recharge when needed.
