Senior Quality Engineer — Pack Assembly & Process Lead

Form Energy; Weirton (WV); On-site; USD 90,000 - 140,000; Full time

Benefits offered by this job

Relocation assistance

Stock options

Comprehensive benefits package

Generous vacation & parental leave

Job summary

Form Energy in Weirton, WV seeks a Senior Quality Engineer to own quality processes for the pack assembly area. You will lead cross-functional teams, drive PFMEAs/Control Plans, and ensure manufacturability and reliability across manual assembly from R&D validation through pilot and high-volume production.

You will run SPC, root-cause analysis, and GD&T-based inspection plans while collaborating with Design/Manufacturing Engineering and suppliers. Relocation assistance is available.

Qualifications

• 3–10 years of quality engineering experience in a manufacturing environment.
• Bachelor's degree in Mechanical Engineering, Electrical Engineering, Materials Science, or related field; advanced degree a plus.
• Solid experience with SPC, PFMEAs, and Control Plans.
• Strong aptitude with electronics 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 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.

Responsibilities

• 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

Skills

Quality engineering

SPC

PFMEA

Control Plans

DOE

8D problem solving

CpK / Ppk

Data analysis (JMP / R / Minitab)

GD&T interpretation

Electronics test & measurement

Wiring diagrams reading

MSA/GR&R

Education

Bachelor's degree in Mechanical Engineering

Bachelor's degree in Electrical Engineering

Bachelor's degree in Materials Science

Advanced degree recommended

Tools

JMP

R

Minitab

Job description

Form Energy in Weirton, WV seeks a Senior Quality Engineer to own quality processes for the pack assembly area. You will lead cross-functional teams, drive PFMEAs/Control Plans, and ensure manufacturability and reliability across manual assembly from R&D validation through pilot and high-volume production.

You will run SPC, root-cause analysis, and GD&T-based inspection plans while collaborating with Design/Manufacturing Engineering and suppliers. Relocation assistance is available.