Controls Engineering Associate Manager, Sustaining

Are you ready to build America’s energy future? Form Energy is an American manufacturing and energy technology company. We’re revolutionizing energy storage with cost-effective, multi-day technology designed to keep the electric grid secure and reliable, even during extended periods of stress. By strengthening the electric system and reimagining what’s possible, we’re giving clean energy a whole new form! 

In recent years, Form Energy has earned a number of accolades, including being named by TIME as a “Best Invention”, MIT Technology Review as a “Top Climate Tech Company To Watch”, and Fast Company as “One of the Next Big Things In Tech”. We are making rapid progress on our mission of delivering energy storage for a better world, and our team is growing just as rapidly to meet demand. We have signed contracts with leading electric utilities across the United States and production of our iron-air batteries is underway at our first high-volume manufacturing facility in West Virginia.

Working for Form Energy is more than just a job, it’s a chance to be part of something extraordinary. And now - right as we significantly scale up battery manufacturing -  might be the most exciting moment in the company’s history to join. We are assembling a team of highly talented and driven individuals across the country. Driven by our core values of humanity, excellence, and creativity, our team is determined to deliver on our mission and transform the energy landscape for the better.

Feeling energized to make a meaningful impact on the world? Then keep reading - you’ve come to the right place.

Role Description

We are looking for an experienced controls engineering manager to join the Manufacturing Control and Execution Systems - Sustaining team. In this role you will lead Controls, Robotics, and SCADA Technicians and will take ownership of both maintenance and continuous improvement of novel equipment used to manufacture Form Energy’s Iron-Air battery. This role offers an exciting opportunity to be part of a mission critical team that owns control and execution systems throughout their lifecycle including design, development, deployment, and sustaining.

Reporting to our Senior Controls Engineering Manager, Manufacturing Control and Execution Systems, you will be part of a quickly-growing manufacturing control and execution systems sustaining team. In this leadership role, you will coordinate with the Manufacturing Control and Execution Systems Senior Controls Engineering Manager and with System Managers to prioritize continuous improvement projects and sustaining activities. You will have opportunities in this role to lead design and develop innovative solutions, as we work together to deploy manufacturing equipment control and execution systems and to make continuous improvements to our equipment, processes, and systems. This is a leadership role where you will have the opportunity to lead multiple continuous improvement projects while mentoring technicians both technically and professionally.

Bringing your extensive experience in control system programming, commissioning, and troubleshooting; you will work closely with a variety of teams, both technical and operational, at Form Factory 1.

This opportunity is based out of Form Factory 1 – Form Energy’s 550,000-square-foot, state-of-the-art manufacturing facility located in Weirton, WV, a commutable distance from Pittsburgh. Purpose-built for high-volume, advanced battery production, Form Factory 1 is a hub of fast-moving, collaborative work driving a new era of large-scale American energy manufacturing in the heart of the Rust Belt.

Relocation assistance is available.

What you'll do:

• Lead Manufacturing Control and Execution Systems sustaining efforts at Form Factory 1 which includes the following:

  • Responsible for maintaining and troubleshooting industrial controls equipment

  • Provide electrical and controls support for the production operations and maintenance departments, including troubleshooting control, electrical issues, and problem resolution as they relate to equipment and process downtime, throughput improvement, and/or any safety concerns

  • Ensure plant automated equipment is functioning as designed/required

  • Responsible for minor PLC and HMI software changes, including continuous improvement initiatives, and troubleshooting of existing equipment

  • Utilize input from production, maintenance supervisors, operators, vendors, and service providers to provide troubleshooting assistance and make improvements

  • Work with Engineers and other Technicians on new automated process equipment for deployment into production

  • Troubleshooting MES data transactions within PLC programs

  • Work with engineers to layout and fabricate machine control panels

• Provide technical guidance and mentorship to less experienced technicians and engineers

• Coordinate with System Managers to assure Controls, Robotics, and SCADA Technicians have the training needed to support manufacturing equipment located throughout Form Factory 1

• Assure Technicians understand the support escalation process and when to bring in on-call engineering support during off-hours

• Maintain spare parts inventory for control, robotic, and SCADA systems

• Assure technicians are properly utilizing Octoplant to access and backup programs

• Utilize input from production, maintenance supervisors, operators, vendors, and service providers to provide direction to controls teams as well as troubleshooting assistance to make improvements

• Responsible for following and assuring team members comply with all Safety and Environmental policies and procedures

• Provide Project Management and Technical Management on multiple continuous improvement projects

• Resource planning to assure production coverage

• Set performance goals and provide timely feedback to team members

• Resolve conflicts amongst team members

What you'll bring:

• A hands-on, lead-by-example leadership style

• 8+ years of experience as a hands-on engineer working on automation and/or electromechanical systems.

• 2+ years of experience hiring and managing a team of engineers and technicians.

• Strong technical communication skills, both written and verbal.

• Excitement and willingness to lead a rapidly growing multi-disciplinary team with a focus on sustaining

• PLC Programming and Troubleshooting

  • Siemens TIA-Portal (Required, execute independently)

  • Rockwell Studio 5000 (Required, execute independently)

  • Beckhoff TwinCat (Nice to Have)

• SCADA/HMI Systems

  • Ignition Perspective (Required, execute independently)

  • Siemens WinCC (Required, with supervision)

  • Rockwell FTView ME (Required, with supervision)

  • IPC and Panel PC setup and deployment (Required, with supervision)

• Robotics

  • FANUC (Required, with supervision)

  • Epson (Nice to Have)

  • Kawasaki (Nice to Have)

• Vision

  • Keyence and Cognex Barcode Scanner (Required, execute independently)

  • Keyence and Cognex Inspection (Nice to Have)

  • Position (Nice to Have)

• MES

  • PLC Product Tracking Programming (Required, execute independently)

  • PLC Handshake/Data Programming (Required, execute independently)

  • Ignition Integration for Data (Required, execute independently)

  • Quickbase (Nice to Have)

• Electrical

  • AutoCAD Electrical Design (Nice to Have)

  • SolidWorks Design (Nice to Have)

  • Review/Redline/Read Electrical Schematics (Required, can train others)

  • Troubleshoot (Required, can train others)

• OT Network

  • Configure Siemens Scalance Managed Network Switches (Nice to Have)

  • Troubleshoot (Required, execute independently)

• Functional Safety (ProfiSafe, CIP Safety, Hardwired)

  • Electrical and Hardware selection and design (Nice to Have)

  • Siemens ProfiSafe and Safety Programming (Required, execute independently)

  • Rockwell CIP Safety and Safety Programming (Required, execute independently)

  • FANUC DCS Programming (Required, execute independently)

• Review Electrical, Hardware, and Programming (Required, execute independently)

• Troubleshoot (Required, execute independently)

• iba (Required, execute independently)

• Octoplant (Required, execute independently)

• Problem-solving

  • Read and interpret schematics, diagrams, and blueprints to troubleshoot and repair controls components (Required)

  • Attention to detail when testing and troubleshooting (Required)

• Recording data and documenting procedures (Required)

• Bachelor Degree in Electrical/Controls/Mechatronics or equivalent experience

• Extensive controls experience in a Manufacturing Environment

#LI-Onsite

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Humanity is a cornerstone of Form Energy’s culture, and we make sure our compensation and benefits reflect that. Form Energy offers competitive salaries, stock options, and a holistic benefits package to ensure all employees have what they need to thrive while working here. 

When it comes to you and your family’s health, we cover 100% of medical, dental, and vision premiums for full-time employees - and 80% of healthcare premiums for dependents. This starts from day one. We also offer at least 12 weeks of paid leave for new parents (up to 20 weeks for birthing parents), and generous vacation policies to give employees time to recharge when needed. 

To build America’s energy future, we need everyone at the table. We are proud to be an equal opportunity employer, and encourage candidates from all backgrounds to apply to our open jobs.

If you may require reasonable accommodations to participate in our interview process, please contact [email protected]. Requests for accommodations will be treated with discretion.

Form Energy is committed to maintaining the privacy of our applicants. Please be aware that we will never solicit sensitive personal information such as Social Security numbers or bank account details during the recruiting or hiring process.