Senior Process Engineer, Mechanical Assembly at Formenergy (Weirton, WV)Senior Process Engineer, Mechanical Assembly

As a Senior Process Engineer, Mechanical Assembly, you will play a key role in advancing the performance, reliability, and efficiency of our production operations. You'll bring a strong mechanical aptitude and data-driven mindset to analyze operational performance, identify opportunities for improvement, and implement robust, high-impact solutions on the floor. Working closely with cross-functional engineering teams, you will drive continuous improvement initiatives and translate operational insights into meaningful change. You will also serve as a key partner to our systems design team, championing human-centered design principles and providing manufacturing feedback that shapes next-generation equipment — strengthening the manufacturing capabilities that keep our multi-day storage systems reliable at scale.

What you'll do:

• Mentor and direct a tactical team of technicians to stabilize line cadence, troubleshoot downtime, and maintain operational continuity
• Own line metrics — track and analyze OEE, yield, and cycle times to identify bottlenecks and implement data-driven improvements
• Evaluate and vet solutions, applying strong mechanical intuition to assess equipment and process issues on the fly and ensure fixes are robust, safe, and effective
• Drive cross-functional resolution, partnering with sister engineering and manufacturing teams to quickly unblock production constraints impacting quality and throughput
• Foster continuous improvement by initiating tactical CI projects on the floor to eliminate waste, improve operator ergonomics, and optimize machine reliability
• Bridge the gap to design by acting as the voice of the shop floor, surfacing human factors and usability challenges to the systems engineering team

What you'll bring:

• Bachelor's degree in Mechanical, Manufacturing, Industrial Engineering, or a related technical discipline
• 3-7 years of hands-on experience in a manufacturing, production, or fast-paced industrial operations environment
• Demonstrated ability to manage, prioritize tasks for, and develop a technical team
• Strong familiarity with manufacturing metrics (OEE, downtime tracking) and a practical, root-cause approach to problem-solving
• Solid understanding of mechanical systems and automated equipment, with the confidence to vet technical solutions and guide floor-level fixes
• Exceptional interpersonal skills, with the ability to influence cross-functional peers and present clear improvement ideas to design engineers
• A proactive, get-it-done attitude, intellectual curiosity, and comfort thriving amid ambiguity as we scale our technology

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.

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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 accommodations@formenergy.com. 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.