Sr. Process Engineer, Body in White, Semi
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About The Position
As a Senior Process Engineer in the Body in White manufacturing operations at Tesla, you will play a crucial role in implementing, developing, and optimizing production methodologies. Your primary responsibility will be to enhance Overall Equipment Effectiveness (OEE) and drive process optimization through various means, including tool and fixture selection, line layouts, ergonomic studies, and material presentation. You will collaborate closely with Design, Test, and Quality Engineering teams to address challenges, improve manufacturability, and foster a culture of continuous improvement. Your efforts will be pivotal in sustaining production lines while focusing on cost reduction and yield improvements. In this role, you will be tasked with developing production lines from the pilot stage to full-scale production. This involves working alongside vendors and manufacturing engineering teams to ensure a seamless transfer of knowledge for sustaining production lines. You will conduct process analyses, design of experiments (DOE), process failure mode and effects analysis (PFMEA), line balancing activities, and capacity modeling. Additionally, you will provide design for manufacturability (DFM) input to the design team to facilitate process and yield improvements. Your responsibilities will also include modifying line and workstation layouts to optimize material flow, reduce waste, and enhance ergonomics, all while adhering to Lean Manufacturing best practices. You will analyze and optimize production processes to ensure safety and maximize OEE in a cost-effective manner, striving to achieve world-class quality levels. As a champion of continuous improvement projects, you will focus on maximizing yield, capacity, and capability. Diagnosing issues during the part manufacturing process will be a key aspect of your role, requiring you to drive corrective actions back to the source for root cause identification and elimination. You will utilize structured problem-solving techniques such as DMAIC, Ishikawa, Five Why (5W), and Eight Disciplines (8D) to achieve these goals. Furthermore, you will analyze data from various sources to identify trends in build quality and efficiency, developing robust data collection, visualization, and analysis tools to enable data-driven operational and financial decisions. Supporting activities for Engineering and Manufacturing will also be part of your responsibilities, including 5S and Lean manufacturing activities, material handling improvements, production line configuration, and safety procedures. You will monitor and reduce process variation using techniques such as Statistical Process Control (SPC) and Measurement Systems Analysis (MSA), ensuring that product specifications and standards are consistently met. Your role will involve creating and maintaining Manufacturing Instructions, routings, and associated processes, as well as developing and training Sustaining Technicians and assisting in the training of Operators as needed. You will also manage activities for Process Sustaining Technicians to support day-to-day coverage of the production line, including developing and documenting appropriate rework procedures. Lastly, you will support 24/7 production operations, ensuring that all processes run smoothly and efficiently.
