Sr. Process Engineer, Energy Products

Tesla - Sparks, NV

Full-time - Mid Level

Sparks, NV

Transportation Equipment Manufacturing

About the position

The Sr. Process Engineer will be a key member of the Production Engineering team at Tesla, focusing on the Energy Cell manufacturing operations. This role involves implementing, developing, and optimizing production methodologies to enhance product flow and efficiency. The engineer will lead initiatives for product optimization, new product introduction, and process improvements while mentoring junior engineers and collaborating with external vendors on automated manufacturing equipment. The position requires a strong emphasis on continuous improvement, data analysis, and cross-functional collaboration to ensure high-quality manufacturing processes.

Responsibilities

• Lead cross functional teams in the development of Process Flows, Control Plan, GR&R, Work Instructions, Process capability, Rework Procedures, Calibration and Qualification of tools, Quality Validation, Risk Assessments (PFMEA) & New product introduction
• Collaborate with Original Equipment Manufacturers in the commissioning and start of production of new automated manufacturing equipment
• Collaborate with EHS in the identification, prevention, and mitigation of safety hazards, proposing and implementing engineering solutions
• Create and implement mentorship programs for Jr Engineers, emphasizing product knowledge and process initiation
• Develop expertise in manufacturing processes and understand process capabilities through critical data analysis
• Develop and modify line layouts, including material flow, waste reduction, and ergonomics, utilizing Lean Manufacturing best practices
• Participate in the transition of a product from concept to pilot line production and into mass manufacturing
• Analyze and optimize production processes to ensure safety while maximizing Overall Equipment Effectiveness (OEE)
• Champion continuous improvement projects (CIP) to maximize yield, capacity, and capability
• Lead engineering teams to execute complex projects while maintaining clear communication channels and detailed reporting to senior management
• Lead cross functional collaboration efforts in the identification, improvement, and mitigation of KPI indicators such as scrap and product cost
• Analyze data from various sources to identify trends in build quality and efficiency
• Develop robust and clear data collection, visualization, and analysis tools
• Monitor and reduce process variation using techniques such as Statistical Process Control (SPC) and Measurement Systems Analysis (MSA)
• Participate in the development and maintenance of FMEAs and Control Plans
• Support 24 by 7 production operations

Requirements

• 6+ years working on processes within high volume automation and/or electro-mechanical production systems
• Bachelor's Degree in Engineering, or equivalent relevant experience
• Experience developing and improving processes with a track record of Overall Equipment Effectiveness improvement activities
• Good understanding of Bill of Materials, Manufacturing Execution System, Specification Management, Change Point Management
• Data collection and analysis experience with the ability to develop data driven root cause analyses and solutions
• Strong problem-solving skills and aptitude for learning systems quickly
• Ability to utilize structured problem-solving techniques such as DMAIC, Ishikawa, Five Why (5W) or Eight Disciplines (8D)
• Exceptional capacity for managing simultaneous activities, competing priorities and challenges
• Strong ability to work and communicate effectively with team and peers within a manufacturing and engineering organization
• Creative capacity for developing new ways to do things better, cheaper, faster
• Passion for making fantastic new products and using testing to achieve outstanding quality, reliability and excellence

Nice-to-haves

• Experience on winding systems, industrial roll to roll or web handling
• Experience on X-ray imaging, Vision systems, Laser process, Laser welding or similar
• Overall experience on power electronics, electrical measurements, testing and metrology systems

Benefits

• Health insurance
• 401k plan
• Paid holidays
• Flexible scheduling
• Professional development opportunities