Senior Manager, Process Engineering

Are you ready to build America’s clean energy future with the team that will deliver? Form Energy is an American energy technology and manufacturing company. We are pioneering a new class of iron-air batteries to enable our electric grid to run on renewable, reliable, and affordable energy, every day of the year. 

Form Energy has been recognized by TIME as “One of the Best Inventions of 2023” for its battery technology and by MIT Technology Review as a “Top Climate Tech Company to Watch”. We are making rapid progress on our mission of delivering energy storage for a better world, and are growing just as rapidly to meet demand. Our team has more than doubled in size in the past year, and continues to expand every day. We have signed contracts with leading electric utilities across the United States. Pilot production of our iron-air batteries has already begun, and later this year, production will take off to high volumes at our new factory in West Virginia. 

Working for Form Energy is more than just a job, it’s a chance to be part of something extraordinary. And right now might be the most exciting moment in the company’s history to join. We are assembling a team of some of the most talented and motivated 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

The Senior Manager of Manufacturing Process Development will play a crucial role in advancing battery assembly processes from prototype to high-volume production. This position requires a strategic, hands-on, and empathetic leader who can build and guide a team of manufacturing and process development engineers to conceptualize, validate, and implement cutting-edge manufacturing techniques. You will lead the development and optimization of manufacturing processes, improve product quality, maximize process capability and reduce the risk of our manufacturing process ahead of high-volume production.

This opportunity is based out of Form Factory 1 in Weirton, WV. Relocation assistance is available.

What you'll do:

• Ensure highly capable processes are developed and demonstrated ahead of detailed equipment design. Measure process capability and evaluate limit samples.

• Internalize responsibility to factory production metrics during equipment design (quality, yield, rate, and availability).

• Build and lead a world-class manufacturing development team responsible for deploying cell and module assembly processes from prototype to high-volume manufacturing.

• Drive PFMEA (Process Failure Mode Effects Analysis) and OEE (Overall Equipment Effectiveness) considerations as early as possible in product development to simplify, reduce non-value add steps, and achieve significant performance/quality/cost improvements.

• Utilize statistical analysis tools and methodologies to analyze process data, identify trends/correlations, and make data-driven decisions for process optimization.

• Partner with product design, R&D, quality, and supply chain teams to integrate DFM (Design for Manufacturing) considerations, process control, and simplicity to enable high volume and cost targets.

• Actively engage with vendors to ensure the selection of appropriate technology, automation levels, and pricing for the scale and maturity of the production line.

• Define, develop, and implement metrology, quality control methods, statistical process control, and inspection methods (incoming, outgoing, and in-process) to ensure process capability and reliability.

• Conduct process capability studies, utilize statistical analysis tools (e.g., Design of Experiments). Lead troubleshooting efforts to identify root causes of manufacturing issues and implement corrective actions to prevent recurrence while optimizing processes.

• Own the process of handing off stable manufacturing systems to operations teams.

What you'll bring:

• 10+ years of manufacturing experience, ideally in automation and assembly environments.

• Proven experience in building and leading a manufacturing engineering team.

• Hands-on experience in high-volume manufacturing, particularly in battery manufacturing or a related industry.

• Expertise in driving process and equipment maturity, process optimization, and cost reduction while maintaining or improving product quality.

• Experience in championing DFM and effective transition of manufacturing systems to operations teams.

• Experience with line design, installation, commissioning, and production ramp.

• Experience in custom manufacturing equipment design and development in partnership with equipment suppliers and automation vendors.

• Proven track record in statistical analysis and quality management systems for process improvement.

• Strong leadership and mentoring abilities, fostering a culture of continuous learning and innovation with a bias for action and first principles mindset.

• Excellent communication skills for effective collaboration with multidisciplinary teams and conveying technical concepts to diverse stakeholders.

• Proficiency in process engineering principles, statistical analysis, and quality management systems.

• Bachelor’s degree in Mechanical engineering, Chemical Engineering, Materials Science, Metallurgy, or a related field.

#LI-Onsite

#LI-DL1

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 a clean and equitable energy future, we need everyone at the table. We strive to form a team as diverse as the communities we will serve with our technology, and are committed to maintaining an inclusive environment for all employees. We are proud to be an equal opportunity employer, and encourage candidates from all backgrounds to apply to our open jobs.