Director of Quality Assurance

Director of Quality Assurance

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 Quality Assurance (QA), to lead the QA resources and assets. The Director of Quality Assurance is responsible for leading the development, implementation, and continuous improvement of quality systems and processes for a lithium-ion (Li-ion) battery manufacturing facility. This role ensures that all products meet stringent safety, regulatory, and customer requirements while driving operational excellence and a culture of quality across the organization.

This role is a critical leadership position responsible not only for managing quality, but for building and scaling the quality function from early-stage ramp through full production in a high-growth, next-generation battery manufacturing environment.

The Director of Quality Assurance will report to the Chief Operating Officer of Forge Battery.

Essential Functions:

• Develop and execute the plant's quality strategy aligned with corporate objectives.
• Lead and mentor the QA/QC teams, fostering a culture of accountability, continuous improvement, and operational excellence.
• Serve as a key member of the plant leadership team, contributing to overall business strategy.
• Own the long-term vision for building and scaling the quality organization, systems, and talent to support multi-GWh production growth.
• Drive enterprise-level quality initiatives across Engineering, Operations, and Supply Chain to ensure alignment on product and process excellence.
• Establish, implement, and maintain robust QMS in compliance with industry standards (e.g., ISO 9001, IATF 16949, ISO 14001).
• Ensure adherence to regulatory and safety requirements specific to Li-ion battery manufacturing.

Quality Management Systems (QMS)

• Oversee document control, change management, and internal audit programs.
• Design and evolve scalable quality systems capable of supporting rapid production ramp, process changes, and product evolution.
• Ensure systems are structured to support data-driven decision-making and real-time performance visibility.

Product & Process Quality

• Drive quality assurance across all stages: incoming materials, in-process production, and final product testing.
• Implement advanced quality tools (e.g., Six Sigma, SPC, FMEA, root cause analysis).
• Lead efforts to reduce defects, scrap, and rework while improving yield and reliability.
• Partner closely with Engineering to influence Design for Manufacturability (DFM) and Design for Quality (DFQ) initiatives.
• Support the transition of new products and processes from development into production, ensuring robust quality validation and control plans.
• Operate effectively in non-steady-state manufacturing environments, managing variability, process instability, and yield ramp challenges.

Customer & Supplier Quality

• Act as the primary quality liaison with customers, addressing complaints, audits, and corrective actions
• Oversee supplier quality management, including qualification, audits, and performance monitoring.
• Ensure timely resolution of non-conformances and implementation of corrective/preventive actions (CAPA).
• Lead customer qualification efforts and ongoing quality performance for high-reliability end markets (e.g., defense, aerospace, energy).
• Establish rigorous supplier development and quality assurance processes to support advanced materials and critical components.
• Provide executive-level reporting and insights linking quality performance to overall business outcomes and operational efficiency.

Compliance & Safety

• Ensure compliance with all applicable regulations, including environmental, health, and safety standards.
• Support product certification processes (e.g., UL, IEC standards for battery systems).
• Lead risk assessments and ensure safe manufacturing practices.
• Own product safety, reliability, and risk mitigation strategies for lithium-ion battery systems in safety-critical applications.
• Drive proactive failure analysis and reliability testing methodologies to ensure long-term product performance.

Continuous Improvement

• Champion Lean Manufacturing and continuous improvement initiatives across the plant.
• Utilize data analytics and KPIs to monitor performance and drive decision-making.
• Lead cross-functional initiatives to improve product quality, process capability, and customer satisfaction.
• Implement advanced analytics, real-time dashboards, and statistical tools to enable predictive quality and performance optimization.
• Drive cost-of-quality reduction initiatives while supporting aggressive production and scaling targets.

Audits & Reporting

• Lead internal and external audits, including customer and regulatory inspections.
• Report on quality metrics, trends, and improvement initiatives to senior leadership.
• Develop and maintain dashboards for real-time quality performance tracking.

Key Performance Indicators

• Product defect rates and yield improvement
• Customer complaints and resolution time
• Supplier quality performance
• Audit results and compliance scores
• Cost of poor quality (COPQ)
• On-time corrective action closure
• Production ramp yield stabilization and process capability improvements
• Product reliability performance and field quality metrics

Required Skills & Experience:

• Must have experience in managing a battery quality assurance team
• Through understanding of quality control standards and methodologies
• Demonstrated project and budget management skills.
• 10+ years of experience in quality assurance within manufacturing; experience in battery, electronics, or automotive industries strongly preferred.
• 5+ years in a leadership role managing quality teams.
• Ability to solve problems and make decisions, as well as think laterally and offer creative solutions to problems.
• Ability to set overall strategy and drive process improvement.
• Excellent oral and written communication skills.
• Strong interpersonal skills with ability to collaborate and build a consensus in a high-pressure environment
• Experience building or scaling quality systems in high-growth or ramp-up manufacturing environments strongly preferred
• Experience operating in complex, technically advanced manufacturing processes with high variability is highly desirable

Education

• Bachelor's degree in Engineering, Materials Science, Chemistry, or related field
• Master's degree preferred.

Key Competencies

• Strategic thinking and execution
• Strong problem-solving and analytical thinking skills.
• Excellent communication and stakeholder management abilities.
• Ability to operate in a fast-paced, high-growth environment.
• Cross-functional collaboration
• Team leadership and talent development
• Enterprise leadership mindset with the ability to influence beyond direct reporting lines
• Data-driven decision-making and analytical rigor

Working Conditions

• 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 the quality function for a next-generation battery platform, playing a critical role in shaping product performance, manufacturing excellence, and long-term company success in a high-growth, high-impact 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.