We're hiring a Staff Process Engineer within our growing Operations Engineering team. In this role, you will serve as a primary technical lead for the automated systems and equipment strategies required to ramp production of our iron air battery. You will own the operation of complex robotic cells and automated hardware, driving technical decisions that eliminate manufacturing bottlenecks and ensure long-term equipment reliability. By continuously improving standards for automation and precision control, you will ensure our production environment delivers a high volume of top quality products. Your leadership will be the cornerstone in transforming advanced battery technology into a world-class, automated manufacturing reality that secures global energy reliability.
What You'll Do- Own and improve semi-manual and automated manufacturing processes for modular products.
- Define and implement OEE and equipment performance metrics to identify loss drivers and prioritize improvement work.
- Collaborate with product design and process development engineering to provide DFM/DFA feedback, ensuring optimization for fully-automated, high-speed manufacturing.
- Drive cross-functional alignment with controls and equipment teams to integrate automation solutions such as torque tools, lift devices, vision checks, interlocks, and other instrumentation.
- Lead root-cause analysis of assembly and quality issues, turning findings into durable automation improvements that ensure safe and repeatable production.
- Support production ramp and sustaining operations, stabilizing builds and reducing variation across shifts
- Mentor and guide multidisciplinary engineering teams, fostering a culture of technical excellence in automated system design and pragmatic problem-solving.
What You'll Bring- Bachelor's degree in Mechanical Engineering, Electrical Engineering, Robotics, Controls, or a related discipline and 7+ years of relevant experience.
- Deep technical understanding of semi-manual and automated assembly processes for complex systems
- Demonstrated expertise with Fanuc Robotics and Siemens PLCs or similar.
- Extensive experience developing assembly methods, tooling, fixtures, and work instructions in an automated production environment.
- Proven track record of providing DFM/DFA feedback to product design and process development teams, influencing part design, interfaces, tolerances, and fastening strategies to improve manufacturability.
- Strong problem-solving skills with the ability to identify and address process, design, and human-factor-driven issues.
- Effective communicator across production, quality, and design teams.
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.
