Senior Process Engineer, Electrode Manufacturing Operations (m/w/d)

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

We are seeking a Senior Process Engineer to join our world-class Operations Sustaining team. Our Operations Sustaining Team is a cross-disciplinary group of experts in Mechanical, Controls Process, and Manufacturing engineering. Together, we're responsible for sustaining, developing, and improving our cutting-edge electrode manufacturing processes for Form Energy's Iron-Air multi-day battery.

As a Senior Process Engineer, you will play a crucial role in optimizing processes for Form Energy's cathode technology. We are looking for someone who has experience developing new technologies from concept to scaled implementation, and a proactive, interdisciplinary approach to problem-solving.

This role will be located at in Weirton, WV, which is just a short drive outside of Pittsburgh, PA. Relocation assistance is available.

What you'll do

• Drive continuous improvements to optimize the electrode production processes, reduce costs, improve quality, and increase efficiency
• Collaborate with cross-functional teams to identify and solve production issues, while maintaining product quality standards
• Conduct root cause analysis as needed in conjunction with various other team members and develop corrective and preventive actions to improve processes, equipment, and systems
• Develop, monitor, and analyze key performance indicators (KPIs) to identify areas for improvement and ensure that targets are met or exceeded
• Ensure compliance with all safety regulations and company policies related to environmental, health, and safety
• Support usage of PLM, MES, and ERP systems, as well as other tools related to manufacturing and sustainability
• Support factory layout/optimization efforts, capacity planning, scalability plans, crew cycling, tool cycling, etc.

What you'll bring

• Direct experience in processes such as powder handling/mixing, roll to roll processing, calendaring or lamination.
• 4+ years of experience in a fast-paced manufacturing or production development environment.
• Bachelor's degree in Chemical Engineering, Materials Science, Chemistry, Mechanical engineering, or equivalent
• Experience with medium to large equipment and desire to roll up your sleeves and fill the gaps where necessary
• Comfort using statistical methods for making process development decisions (using JMP or Minitab or equivalent), with proficiency on SQL data query
• Experience owning manufacturing processes and showing accountability for their quality, throughput, yield, and overall success
• Experience authoring process, safety, and quality documentation for best-in-class practices
• Excellent communication and organizational skills
• Proven experience managing projects, leading teams, and implementing process improvement activities
• Direct experience creating DFMEAs & PFMEAs and implementing controls for risk mitigation
• Experience creating and using SPCs in a production environment
• Ability to lead and train a new team in industrial manufacturing and quality best practices

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.