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Form Energy is hiring a Senior Supplier Engineer, Structural Components to support the transfer of structural assemblies—including stamped, laser-cut, welded, plated, and bent parts—to manufacturing suppliers. Reporting to the Global Supply Management team within the Supplier Industrialization Engineering group, you will manage new product introduction from concept through production at supplier facilities, with emphasis on cost-effectiveness and design-for-manufacturing (DFM) analysis to identify and mitigate manufacturing risks.
Key responsibilities include collaborating with Design and Advanced Manufacturing teams to co-develop pack-level structural designs (base, roof, tower, cabinets) optimized for structural integrity, heavy-gauge fabrication, and modular system integration. You will lead DFM and APQP reviews with structural suppliers, focusing on welding feasibility, tube/C-channel bending constraints, and large-scale assembly tolerances. You own the Quality Maturation Level (QML) and PPAP roadmap, systematically qualifying supplier Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR), and Welder Performance Qualifications (WPQ).
You will partner with suppliers to establish robust weld verification programs, defining requirements for weld characterization, destructive testing (macro-etch, tensile), and Non-Destructive Testing (NDT) such as ultrasonic, magnetic particle, or liquid penetrant inspection. You will proactively identify and mitigate program schedule risks unique to heavy manufacturing, including long-lead raw steel mill runs, supplier crane/handling limits, and large-component shipping/validation constraints. You will drive closed-loop Non-Conformance Management by issuing SCARs, leading suppliers through formal root cause analysis for structural or weld defects, and verifying process control plans via on-site audits of welding, fixturing, and coating processes.
Required qualifications: 5+ years in supplier quality, industrialization, or manufacturing engineering specializing in heavy-gauge structural steel and large welded assemblies. Bachelor's degree in Mechanical, Metallurgical, Welding, or Manufacturing Engineering or related technical field. Demonstrated expertise in structural fabrication processes including heavy plate/structural steel forming, laser/plasma cutting, and multi-pass welding. Strong working knowledge of welding standards (AWS D1.1, ASME Section IX), weld inspection methods (NDT/destructive), and WPS/PQR qualification. Strong understanding of geometric dimensioning and tolerancing (GD&T) principles applied to large, multi-part structural weldments. Proven ability to manage technical supplier relationships, lead on-site process control audits, and drive robust root cause investigations (8D, 5-Why). Relocation assistance available.
