Role DescriptionForm Energy is hiring a Staff Process Engineer to serve as process lead for Form's high-volume cathode assembly line. In this role, you will be involved from the earliest stages of manufacturing development - defining process requirements, designing the manufacturing process, and building the line model - through to commissioning and handoff to production operations. You will own line capacity modeling, PFMEA generation and risk management, proof of concept testing, as well as aiding in vendor selection and management with the support of the project automation & equipment lead.
The ideal candidate has extensive experience with high-volume assembly processes, hands-on experience in laser welding and vision/inspection systems, and strong project and vendor management skills. If you have a track record of taking a process from a conceptual throughput model through line commissioning and ramp, and enjoy owning a line end-to-end, we want to hear from you.
Relocation assistance is available.
What you'll do:- Serve as process engineering line lead, owning the manufacturing process for a complex multi-step assembly line from early concept through production ramp
- Develop line models to validate throughput, cycle time, staffing, and capacity assumptions ahead of equipment build
- Engage early with design engineering to influence product and process requirements for manufacturability, and generate and maintain PFMEAs to drive design and process decisions
- Support development of detailed user requirement specifications (URS) and factory and site acceptance testing plans (FAT/SAT); support management of vendors and integrators through equipment design, build, delivery, and commissioning
- Lead proof of principle testing to validate equipment and process design choices early in the design phase, with support from internal process development and mechanical design resources
- Onboard and direct a team of process development and operations engineers onto the line at FAT; generate clear documentation, deliverables, and work breakdown structures to bring a team up to speed quickly
What you'll bring:- 4+ years of experience in manufacturing in a process engineering or operations role, ideally with high-volume assembly processes
- Demonstrated experience leading a process line from early design through commissioning and ramp, including line modeling and capacity planning
- Strong track record generating PFMEAs and applying them to drive design and process decisions
- Experience across equipment procurement, vendor management, and commissioning (URS, FAT/SAT), with proven project management and organization skills
- Hands-on experience with laser welding processes and with vision and high-volume in-line inspection systems strongly preferred
- A solid technical background with the ability to communicate and collaborate effectively across disciplines
- Degree in Mechanical or Manufacturing engineering
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
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.
