Role DescriptionWe are hiring a Senior Quality Engineer to serve as the quality engineering owner for our Pack assembly area. You will develop and own quality processes and methodologies, lead cross-functional teams, and partner with Design Engineering, Manufacturing Engineering, Suppliers, and Operations to address quality, reliability, and manufacturability challenges across a manual assembly environment. This is a hands-on individual contributor role spanning the full product development lifecycle - from R&D validation through pilot and high-volume production. You will be a critical member of Form Energy's Quality Team, ensuring pack assemblies consistently meet customer and internal requirements. Relocation assistance is available.
What you'll do:- Own and drive quality processes and documentation for pack assembly, including Control Plans, PFMEAs, and inspection/test methods
- Lead change management and support execution of process development experiments in the pack assembly area
- Regularly review and revise PFMEAs and Control Plans to reflect process changes and lessons learned
- Lead identification and resolution of manufacturing quality issues, including root cause analysis and corrective actions
- Drive continuous improvement activities in partnership with Design/Manufacturing Engineering and external Suppliers
- Lead Statistical Process Control (SPC) activities and apply critical thinking to reduce variation in manual assembly processes
- Lead non-conforming material control activities for pack assemblies and sub-components
- Develop, qualify, and maintain manual inspection methods and visual inspection standards for pack assembly operations
- Define GD&T-based inspection plans and ensure dimensional conformance of structural and mechanical components
- Develop test plans and inspection procedures for electronics components - including PCBs, connectors, sensors, and wiring harnesses - within the pack
What you'll bring:- 3-10 years of quality engineering experience in a manufacturing environment
- Bachelor's degree in Mechanical Engineering, Electrical Engineering, Materials Science, or a related field; advanced degree a plus
- Solid experience with SPC, PFMEAs, and Control Plans
- Strong aptitude with electronic test and measurement systems
- Proficiency in reading and interpreting mechanical drawings and wiring diagrams
- Structured problem-solving (8D) and strong statistical skills including DOE, Process Capability (Cpk, Ppk), etc.
- Proficiency with data analysis tools such as JMP, R, Minitab, or equivalent
- Ability to manage, synthesize, and interpret data from manual assembly processes
- Proficiency in GD&T (Geometric Dimensioning and Tolerancing) and experience defining dimensional inspection plans for structural mechanical components
- Experience with electronics component inspection and testing - developing functional test methods and in-process inspection criteria for PCBs, connectors, sensors, or wiring harnesses is strongly preferred
- Experience with attribute and variable measurement system analysis (MSA/GR&R) for manual and instrument-based inspections
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.#LI-Onsite
#LI-JM2
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.
To build America's energy future, we need everyone at the table.
