Senior Quality Engineer, Cell Assembly

Role Description

We are hiring a Senior Quality Engineer to serve as the quality engineering owner for our Cell Assembly manufacturing area. You will develop and own quality processes and methodologies, lead cross-functional teams, and partner with Design Engineering, Manufacturing Engineering, Suppliers, and Operations to address quality, reliability, and manufacturability challenges on a high-automation, high-volume production line. This is a hands-on individual contributor role spanning the full product development lifecycle — from R&D validation through pilot and high-volume production. You will be a critical member of Form Energy's Quality Team, ensuring cell assemblies consistently meet customer and internal requirements.

What You'll Do

• Own and drive quality processes and documentation for cell assembly, including Control Plans, PFMEAs, and inspection/test methods
• Lead change management and support execution of process development experiments in the cell 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 systematically reduce variation on high-automation, high-volume production lines
• Lead non-conforming material control activities for cell assemblies and sub-components
• Define, validate, and maintain quality controls and measurement/test methods for resistance welding and laser welding operations
• Partner with automation and equipment engineering teams to embed quality controls into high-volume production systems

What You'll Bring

• 3–10 years of quality engineering experience in a manufacturing environment (P3: 3–5 years; P4: 5–10 years)
• Bachelor's degree in Mechanical Engineering, Electrical Engineering, Materials Science, or a related field; advanced degree a plus
• Solid experience with SPC, PFMEAs, and Control Plans
• Strong aptitude with electronic 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
• Experience with quality engineering in high-automation, high-volume manufacturing environments
• Knowledge of resistance welding or laser welding processes, including process control and quality inspection methods, is strongly preferred

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

Relocation assistance is available.