Staff Reliability Engineer, Energy Products

Tesla•Palo Alto, CA

About The Position

As a Staff Reliability Engineer focusing on Tesla Energy Systems, you will play a key role in designing reliability into Tesla’s industrial and residential products. This role follows the reliability lifecycle of the product from concept to design, development testing/analysis, manufacturing, and field operation to design-in, confirm, and grow exceptional reliability at every stage. You will investigate failures through physics of failure analysis and physical testing to accurately predict the charging system’s robustness and optimize product reliability while accelerating Tesla’s next gen products’ time to market.   Set and communicate reliability requirements and targets for site, product, subsystem, and components Create Fault Trees and reliability block diagrams to assess system reliability and warranty analysis. Facilitate Design FMEA sessions to drive reliable design choices and improve validation test programs Analyze usage and environmental conditions from the field to improve requirement setting and testing methods Apply statistical analysis to test (accelerated life) and field (life) data to inform reliability physics modeling/analyses and associated corrective actions Work closely with Design and Reliability Data Engineers to create/interpret/validate numeric models of fielded and in-test products Specify reliability validation plans for components and subsystems using physics of failure. Provide guidance on sample size requirements and durations for reliability testing using lifetime models and reliability statistics Drive reliability assessments in product design reviews and clearly communicate risk at each phase of product development and for released products Facilitate failure analysis to understand root cause and drive resolution of failures occurring during product development. Research failure mechanisms to build more robust validation plans and influence design choices Influence supplier selection for higher reliability and provide clear guidance on reliability requirements and demonstration to suppliers Provide reliability design guidelines and apply reliability lessons learned to enable continuous improvement. Answer complex questions on fleet usage and behavior to enable proactive health monitoring, grow reliability, and minimize field failures

Requirements

Bachelor of Science in Materials Engineering, Mechanical Engineering, Electrical Engineering or related field and one or more years of industry experience in a reliability engineering role or equivalent experience
Understanding of accelerated testing methods, governing equations, and physics of failure for different failure mechanisms
Understanding of applied statistics and reliability statistics (Weibull distribution, Maximum Likelihood Estimation, Bayesian methods, Monte Carlo analysis, etc.)
Working knowledge of failure analysis techniques such as optical microscopy, SEM, CSAM, X-ray, cross-sectioning and EDX
Knowledge of the ReliaSoft Synthesis Platform, including Weibull++, BlockSim, ALTA, RGA, and xFMEA
Knowledge of methods to design-in reliability, including electronic computer-aided design and mechanical computer-aided engineering (CAE) data into 3D finite element models (e.g. using Sherlock)
Working knowledge of programming languages, preferably Python
Knowledge of reliability growth techniques, such as Crow-AMSAA and Crow Extended is a plus
Knowledge of reliability warranty analysis and reliability prediction methods
Experience working with complex electronic and mechanical systems

Responsibilities

Set and communicate reliability requirements and targets for site, product, subsystem, and components
Create Fault Trees and reliability block diagrams to assess system reliability and warranty analysis
Facilitate Design FMEA sessions to drive reliable design choices and improve validation test programs
Analyze usage and environmental conditions from the field to improve requirement setting and testing methods
Apply statistical analysis to test (accelerated life) and field (life) data to inform reliability physics modeling/analyses and associated corrective actions
Work closely with Design and Reliability Data Engineers to create/interpret/validate numeric models of fielded and in-test products
Specify reliability validation plans for components and subsystems using physics of failure
Provide guidance on sample size requirements and durations for reliability testing using lifetime models and reliability statistics
Drive reliability assessments in product design reviews and clearly communicate risk at each phase of product development and for released products
Facilitate failure analysis to understand root cause and drive resolution of failures occurring during product development
Research failure mechanisms to build more robust validation plans and influence design choices
Influence supplier selection for higher reliability and provide clear guidance on reliability requirements and demonstration to suppliers
Provide reliability design guidelines and apply reliability lessons learned to enable continuous improvement
Answer complex questions on fleet usage and behavior to enable proactive health monitoring, grow reliability, and minimize field failures

Benefits

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