Director of Process Engineering

Director of Process Engineering

Summary:

Forge Battery is a rapidly growing company that is building a multi-GWh battery plant in Morrisville, NC, and is seeking a highly skilled and experienced Director of Process Engineering to optimize the battery manufacturing process while maintaining quality and reducing costs. The Director of Process Engineering will be responsible for identifying process improvements, process validation and implementation.

This role will lead the development, integration, and scale-up of manufacturing processes, with a focus on battery assembly, testing, and integration operations. The Director will play a critical role in building and evolving process engineering capabilities to support production ramp, while managing variability associated with upstream supplier-provided materials and components.

The Director of Process Engineering with report to the Chief Operating Officer of Forge Battery.


Essential Functions:

Lead and manage the battery manufacturing process

• Create a process engineering vision, develop a strategy, and hold teams accountable to deliver high-impact business results (KPIs).
• Implement innovative world class Engineering strategies and tactics
• Establish Key Performance Indicators (KPIs) that yield high-impact business results in a dynamic environment including Target setting, execute to KPI metrics, Plan details to achieve targets, and drive corrective actions as necessary within a Business Operating System (Daily Mgt at floor level)
• Demonstrate adaptability and willingness to take on additional responsibilities as the company expands and evolves.
• Development/compliance/execution of standards for meeting customer requirements, process/product quality, cost control/waste reduction
• Contribute to the integration / execution / compliance regarding APQP principles, and evaluation of our processes to meet product specifications.
• Lead the development and scale-up of assembly, testing, and integration processes, ensuring readiness for high-volume production.
• Define and control critical process parameters across manufacturing operations, with a focus on stability, repeatability, and scalability.
• Manage process variability across both internal operations and incoming materials from external suppliers.

Execute the structure necessary to improve processes and product quality

• Recruit, form, lead, manage, coach and mentor a diverse team in technical and behavioral competencies to develop and implement innovative solutions that deliver world class safety, quality, productivity, cycle time, and cost.
• Lead deployment and assure support/engagement of workshops/projects
• Supporting / enabling ISO certification and compliance
• Teach/mentor/Coach using team-based problem-solving approaches to identify/resolve root causes, and prevent recurrence
• Engage/Advocate/Apply Lean/Shainin/6Sigma tools to achieve targeted improvements
• Develop training network leveraging a train the trainer approach
• Develop a future pathway to support APQP needs (Advanced Quality support needs)
• Establish and standardize robust process validation methodologies, control plans, and operating procedures across assembly and test operations.
• Drive integration between process engineering, quality, and supplier performance to ensure consistent product outcomes.

Budget Management

• Provide accurate and timely financial information to the Finance department, ensuring transparency in budget utilization.
• Build world-class capabilities within our factory that maximize the return on investment of your team with budget responsibility.
• Develop and implement contingency plans as necessary in response to evolving business conditions, ensuring financial resilience, and Risk Mitigation Plans.
• Align process engineering investments with capacity expansion, process scalability, and long-term operational efficiency.

Drive best practice improvement implementation with team

• Develop / oversee improvement project review process
• Insure improvement process ties annually to individual performance planning
• Support the development of a project pool for future improvements.
• Develop, implement process to close performance gaps and implement best practices with launches of all new equipment and processes.
• Benchmark best Process Engineering practices, Collaborate and Communicate between Departments
• Lead commissioning, ramp-up, and optimization of manufacturing equipment supporting assembly and testing operations.
• Ensure repeatability, consistency, and scalability of processes across production lines and future expansions.

Contribute to the development of business plans and budgets

• Work with Leaders/peers on preparing Annual Operating Plan, Strategic Action Plans and Budgets
• Provide input on anticipated improvements to critical KPI metrics
• Connect the Strategic/Business plan to Vital Few annual Priorities within Process Engineering
• Support long-term capacity planning and process scalability aligned with company growth objectives.

Team collaboration and interpersonal skills

• Collaborate cross functionally with other departments to drive alignment and foster a cohesive company culture around delivering new processes and products that meet / exceed customer expectations
• Enable safe delivery of quality products on time to our customers, working at high speed across the entire value stream
• Support delivering a battery factory on time and on budget
• Partner closely with Engineering, Quality, Operations, and Supply Chain to ensure alignment on product integration, process readiness, and supplier performance.
• Work with internal and external partners to ensure successful integration of externally supplied components and materials into manufacturing processes.
• Drive a culture of accountability, data-driven decision-making, and operational excellence.

Required Skills & Experience:

• Prior experience working in a fast-paced, start up, high-growth environment
• 3-5+ years of manufacturing engineering leadership experience
• Proven ability to develop and execute strategic plans that drive success, demonstrates a history of exceeding targets and fulfilling leadership responsibilities as needed.
• Deep understanding and experience driving process and product improvements w/ FMEA, QCP, Gage Control/GR&R, SPC, Minitab
• 1-2+ years in Automotive or Li-ion Battery industry, and/or Operational Excellence roles
• 1-2+ years experience in APQP (Advanced Product Quality Planning) related role
• Current passport, ability to travel globally as the job requires
• Bachelor's degree from an accredited institution in a technical discipline such as the sciences, technology, engineering, or manufacturing
• Relevant experience in high volume production of cylindrical style battery electrodes, cell assembly & testing.
• Experience developing and scaling manufacturing processes in assembly, testing, or precision manufacturing environments strongly preferred.
• Experience working in environments with significant reliance on supplier-provided materials or components preferred.

PREFERRED EXPERIENCE AND QUALIFICATIONS

• Exposure to problem solving environments actively practicing Lean Manufacturing, Shainin Red X, and Six Sigma Process Improvement methodologies
• Advanced degree in Business, or an Engineering discipline, MBA or equivalent
• Relevant experience in pouch style battery electrodes, cell assembly & testing. Module and Pack experience is a plus.
• Track record with successful demonstrated results of managing multiple projects and multitasking
• Exhibit exceptional data analysis, communication skills, diverse teaming and collaboration.
• Ability to make sound and timely judgments in an ambiguous environment with minimal drama.
• Willingness to raise standards each year to drive organizational excellence.
• Ability to convey subtle or complex messages clearly, as appropriate for the topic and audience.
• Balance between demand and capacity when establishing priorities for your organization.
• Application of basic engineering techniques to optimize manufacturing processes.

Education

• Bachelor's degree
• MBA or equivalent graduate degree preferred

Work Environment

• On-site presence required at the North Carolina manufacturing facility.
• Occasional travel to suppliers, partners, or corporate locations as needed.
• Availability to support critical manufacturing operations outside normal business hours when required.

Compensation/Benefits

• Annual 10% bonus based on the successful completion of individual KPIs and company's performance.
• Medical/dental/vision/disability and life insurance, holidays, PTO, Flexible Spending Account and 401(k) plan with company match and additional voluntary benefits.

Opportunity

This is a unique opportunity to build and scale process engineering within a next-generation battery manufacturing platform, playing a critical role in production ramp, process stability, and long-term operational excellence in a high-growth environment.

Forge Battery is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to sex, gender identity, sexual orientation, race, color, religion, national origin, disability, protected Veteran status, age, or any other characteristic protected by law.