Senior Quality Engineer, Pack at Form Energy — Weirton, WV

Role Description

We are hiring a Senior Quality Engineer to serve as the quality engineering owner for our Pack assembly 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 across a manual assembly environment. 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 pack assemblies consistently meet customer and internal requirements. Relocation assistance is available.

What you'll do

• Own and drive quality processes and documentation for pack assembly, including Control Plans, PFMEAs, and inspection/test methods
• Lead change management and support execution of process development experiments in the pack 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 reduce variation in manual assembly processes
• Lead non-conforming material control activities for pack assemblies and sub-components
• Develop, qualify, and maintain manual inspection methods and visual inspection standards for pack assembly operations
• Define GD&T-based inspection plans and ensure dimensional conformance of structural and mechanical components
• Develop test plans and inspection procedures for electronics components — including PCBs, connectors, sensors, and wiring harnesses — within the pack

What you'll bring:

• 3–10 years of quality engineering experience in a manufacturing environment
• 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
• Ability to manage, synthesize, and interpret data from manual assembly processes
• Proficiency in GD&T (Geometric Dimensioning and Tolerancing) and experience defining dimensional inspection plans for structural mechanical components
• Experience with electronics component inspection and testing — developing functional test methods and in-process inspection criteria for PCBs, connectors, sensors, or wiring harnesses is strongly preferred
• Experience with attribute and variable measurement system analysis (MSA/GR&R) for manual and instrument-based inspections

Where you'll work:

#LI-Onsite

#LI-JM2