Sr. Process Engineer, Powdercoat, Megafactory

Tesla•Brookshire, TX

About The Position

A Sr. Process Engineer will implement, develop, and optimize powder coating application in the manufacturing operations of Tesla. This engineer will be responsible for optimizing product flow though the factory though process optimization that may include tool /fixture selection, line layouts, ergonomic study, material presentation, and other relevant factors. They will interface with design, test, and quality engineering to solve problems, improve manufacturability, and implement continual improvement. They will sustain products with cost reduction and yield improvements. In addition, the Sr. Process Engineer will work with quality to compile and evaluate data to determine appropriate limits and variables for process or material specifications. Develop expertise in Powder coating application processes. Understand process capabilities through critical data analysis and in depth understanding of the product. 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 Powder coating application processes to ensure safety while maximizing Overall Equipment Effectiveness (OEE) in cost effective means while driving to achieve world-class quality levels. Champion continuous improvement projects (CIP) to maximize yield, capacity, and capability Responsible for diagnosing issues found during the Powder coating application process and drive corrective action back to source, resulting in root cause identification and elimination. Utilize structured problem-solving techniques such as DMAIC, Ishikawa, Five Why (5W) and Eight Disciplines (8D) Analyze data from various sources to identify trends in build quality and efficiency. Develop robust and clear data collection, visualization, and analysis tools. Enable data driven operational and financial decisions through predictive insights into tool and process performance, including integration of factory data systems and use of software such as MySQL, Python, R, JMP, Minitab, Tableau and Ignition Perform supporting activities for engineering and manufacturing including 5S and Lean manufacturing activities, material handling improvements, production line configuration, and safety procedures Monitor and reduce process variation using techniques such as Statistical Process Control (SPC) and Measurement Systems Analysis (MSA). Monitor and audit manufacturing processes to ensure product specifications and standards are achieved. Participate in the development and maintenance of FMEAs and Control Plans. Analyze, develop, process, and implement Engineering Change Orders Create and maintain Manufacturing Instructions, routings, and associated processes. Develop and train sustaining technicians, assist in the training of operators as needed. Manage activities for process sustaining technicians to support day-to-day coverage of production line, including developing and documenting appropriate rework procedures Support 24 by 7 production operations

Requirements

Degree in Engineering, Mathematics, Physical Science or equivalent experience
Experience developing and improving Powdercoating application processes
Have a demonstrated 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
Ability to develop data driven root cause analyses and solutions and knowledge of Statistical Process Control and its application
Strong problem-solving skills and an aptitude for learning systems quickly
Able to utilize structured problem-solving techniques such as DMAIC, Ishikawa, Five Why (5W) or Eight Disciplines (8D)
Able to resolve high level performance issues into addressable actions
Exceptional capacity for managing simultaneous activities, competing priorities and challenges
Strong ability to work and communicate effectively with team, suppliers and peers within a manufacturing and engineering organization
This includes excellent communication skills: written and verbal
Creative capacity for developing new ways to do things better, cheaper, faster in alignment with the Tesla approach to revolutionary product development
Passion for making fantastic new products and using testing to enable an engineering organization to achieve outstanding quality, reliability and excellence
Working experience on Powder Supply Systems, Powder Reclaim Systems, Dust Collector Systems, Humidifier Systems, IR Ovens, PreTreatment Systems, Conveyor Systems, Robotic, Sealant Dispensing

Responsibilities

Implement, develop, and optimize powder coating application in the manufacturing operations
Optimize product flow though the factory though process optimization that may include tool /fixture selection, line layouts, ergonomic study, material presentation, and other relevant factors
Interface with design, test, and quality engineering to solve problems, improve manufacturability, and implement continual improvement
Sustain products with cost reduction and yield improvements
Work with quality to compile and evaluate data to determine appropriate limits and variables for process or material specifications
Develop expertise in Powder coating application processes
Understand process capabilities through critical data analysis and in depth understanding of the product
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 Powder coating application processes to ensure safety while maximizing Overall Equipment Effectiveness (OEE) in cost effective means while driving to achieve world-class quality levels
Champion continuous improvement projects (CIP) to maximize yield, capacity, and capability
Responsible for diagnosing issues found during the Powder coating application process and drive corrective action back to source, resulting in root cause identification and elimination
Utilize structured problem-solving techniques such as DMAIC, Ishikawa, Five Why (5W) and Eight Disciplines (8D)
Analyze data from various sources to identify trends in build quality and efficiency
Develop robust and clear data collection, visualization, and analysis tools
Enable data driven operational and financial decisions through predictive insights into tool and process performance, including integration of factory data systems and use of software such as MySQL, Python, R, JMP, Minitab, Tableau and Ignition
Perform supporting activities for engineering and manufacturing including 5S and Lean manufacturing activities, material handling improvements, production line configuration, and safety procedures
Monitor and reduce process variation using techniques such as Statistical Process Control (SPC) and Measurement Systems Analysis (MSA)
Monitor and audit manufacturing processes to ensure product specifications and standards are achieved
Participate in the development and maintenance of FMEAs and Control Plans
Analyze, develop, process, and implement Engineering Change Orders
Create and maintain Manufacturing Instructions, routings, and associated processes
Develop and train sustaining technicians, assist in the training of operators as needed
Manage activities for process sustaining technicians to support day-to-day coverage of production line, including developing and documenting appropriate rework procedures
Support 24 by 7 production operations

Benefits

Along with competitive pay, as a full-time Tesla employee, you are eligible for the following benefits at day 1 of hire:
Medical plans > plan options with $0 payroll deduction
Family-building, fertility, adoption and surrogacy benefits
Dental (including orthodontic coverage) and vision plans, both have options with a $0 paycheck contribution
Company Paid (Health Savings Accounts) HSA Contribution when enrolled in the High-Deductible medical plan with HSA
Healthcare and Dependent Care Flexible Spending Accounts (FSA)
401(k) with employer match, Employee Stock Purchase Plans, and other financial benefits
Company paid Basic Life, AD&D
Short-term and long-term disability insurance (90 day waiting period)
Employee Assistance Program
Sick and Vacation time (Flex time for salary positions, Accrued hours for Hourly positions), and Paid Holidays
Back-up childcare and parenting support resources
Voluntary benefits to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance
Weight Loss and Tobacco Cessation Programs
Tesla Babies program
Commuter benefits
Employee discounts and perks program