Staff Process Engineer

Form Energy; Weirton (WV); On-site; USD 120,000 - 160,000; Full time

Benefits offered by this job

Relocation assistance

Job summary

Form Energy in Weirton, WV is hiring a Staff Process Engineer to lead the high-volume cathode assembly line, from concept through production ramp. You will own line modeling, PFMEA generation, and risk management, and work with project automation and equipment leads to guide vendor decisions.

The ideal candidate has 4+ years in manufacturing process engineering or operations with hands-on laser welding and vision/inspection systems, plus strong project management and collaboration skills.

Qualifications

• 4+ years of manufacturing experience in a process engineering or operations role.
• Led a process line from design through commissioning and ramp, including line modeling and capacity planning.
• Proven PFMEA generation and application to drive design and process decisions.

Responsibilities

• Serve as process engineering line lead for a complex multi-step assembly line from early concept through production ramp.
• Develop line models to validate throughput, cycle time, staffing, and capacity.</br>Note: line breaks kept for readability; will be cleaned in final schema.
• Support development of URS and FAT/SAT plans; manage vendors and integrators through equipment design and delivery.
• Lead proof of principle testing early in the design phase with internal teams.
• Onboard and direct a team of process development and operations engineers on the line at FAT; produce documentation and work breakdowns.

Skills

Process engineering

PFMEA

Project management

Vendor management

Laser welding

Cross-functional collaboration

Education

Bachelor's in Mechanical/Manufacturing engineering

Tools

Line modeling software

Vision inspection systems

Laser welding equipment

Job description

Are you ready to build America's energy future? Form Energy is an American manufacturing and energy technology company. We're revolutionizing energy storage with cost-effective, multi-day technology designed to keep the electric grid secure and reliable, even during extended periods of stress. By strengthening the electric system and reimagining what's possible, we're giving clean energy a whole new form!

In recent years, Form Energy has earned a number of accolades, including being named by TIME as a "Best Invention", MIT Technology Review as a "Top Climate Tech Company To Watch", and Fast Company as "One of the Next Big Things In Tech". We are making rapid progress on our mission of delivering energy storage for a better world, and our team is growing just as rapidly to meet demand. We have signed contracts with leading electric utilities across the United States and production of our iron-air batteries is underway at our first high-volume manufacturing facility in West Virginia.

Working for Form Energy is more than just a job, it's a chance to be part of something extraordinary. And now - right as we significantly scale up battery manufacturing - might be the most exciting moment in the company's history to join. We are assembling a team of highly talented and driven individuals across the country. Driven by our core values of humanity, excellence, and creativity, our team is determined to deliver on our mission and transform the energy landscape for the better.

Feeling energized to make a meaningful impact on the world? Then keep reading - you've come to the right place.

Role Description

Form 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. To build America's energy future, we need everyone at the table. We are proud to be an equal opportunity employer, and encourage candidates from all backgrounds to apply to our open jobs. If you may require reasonable accommodations to participate in our interview process, please contact [e-mail]. Requests for accommodations will be treated with discretion. Form Energy is committed to maintaining the privacy of our applicants. Please be aware that we will never solicit sensitive personal information such as Social Security numbers or bank account details during the recruiting or hiring process.