Director of Process Engineering

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At Forge Nano, we solve materials challenges that determine performance, safety, and reliability at scale.

From energy and semiconductors to defense systems, our team works at the atomic level to push what’s possible in the real world.

Full‑Time in Raleigh, NC

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 reports to the Chief Operating Officer of Forge Battery.

• 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.

• 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/6
  
  Sigma 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.

• 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.