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Form Energy is hiring a Senior Industrial Engineer to join Form Factory 1, a 550,000-square-foot high-volume manufacturing facility in Weirton, WV. This role owns the factory's physical layout and standard work, defining how material, people, and equipment flow through the facility today and planning for growth as production scales.
You will be responsible for layout management, maintaining the factory floor layout including equipment placement, material flow, workstation design, storage, and walkways. You'll manage layout change requests and keep documentation current. You will conduct time and motion studies, develop and maintain standard work and labor standards to support line balancing, takt time analysis, and headcount planning.
You'll lead capacity and layout planning for factory expansion and new production lines, including space planning, equipment footprints, utilities, material-handling needs, and phased ramp scenarios. You will build and maintain capacity models and discrete-event simulations to identify bottlenecks, quantify constraints, and evaluate the impact of design and layout decisions before implementation.
Applying lean and continuous improvement methods (value stream mapping, 5S, kaizen, SMED, root cause analysis), you'll reduce waste, cycle time, and rework while improving safety and ergonomics. You'll design efficient material flow, line-side presentation, kitting, and inventory staging in collaboration with Supply Chain and Production Planning. You'll evaluate workstations and tasks for ergonomic risk and partner with EHS to design safe, efficient work areas.
You'll lead small projects and cross-functional working sessions, communicate trade-offs clearly, and mentor junior engineers and technicians in industrial engineering practices. This is an opportunity to shape the growth of a fast-moving company with breakthrough iron-air battery technology and a mission to revolutionize energy storage. Relocation assistance is available.
REQUIREMENTS:
- Bachelor's degree in Industrial Engineering, Manufacturing Engineering, Mechanical Engineering, or related field
- 5+ years of industrial engineering experience in a manufacturing environment, with hands-on experience in layout design, time studies, and process improvement
- Demonstrated experience developing and managing factory layouts, ideally using CAD tools (AutoCAD, Visio, Revit) and taking facility expansions from concept to implementation
- Proficiency in time and motion studies, standard work development, line balancing, and labor modeling
- Working knowledge of lean manufacturing and Six Sigma tools; certification (Green Belt or higher) is a plus
- Strong data analysis and modeling skills with ability to turn complex data into clear recommendations; experience with Excel, SQL, Python, or simulation software (FlexSim, Simio) is a plus
- Excellent written and verbal communication with ability to work effectively with production floor, engineers, and senior leaders
