Sr. Process Engineer, Battery Pack

A Sr. Process Engineer will develop, implement, and optimize production methodologies in Tesla manufacturing operations. They will be responsible for sustaining battery pack production processes through the product life cycle, interfacing with design, test, and quality engineering to improve manufacturability, and implement continual improvement.
In addition, the Sr. Process Engineer will be responsible for compiling and evaluating production data to determine appropriate limits and variables for processes and material specifications as part of cost reduction and yield improvements.

Responsibilities

• Develop expertise in battery pack manufacturing processes. Understand process capabilities through production data analysis and in depth understanding of the product. Develop and modify process flow, line layouts and material flow, utilizing Lean Manufacturing best practices
• Analyze and optimize production 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 to maximize yield, capacity, and process capability
• Responsible for diagnosing issues found during the part manufacturing 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)
• 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
• 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. 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 or equivalent relevant experience
• Knowledge of Statistical Process Control and its application
• 7+ years in a high volume, highly automated manufacturing facility developing and improving processes
• Experience developing and improving Process. Have a demonstrated track record of Overall Equipment Effectiveness improvement activities
• 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 investigate production performance issues and distil problem statements into addressable actions
• Experience in the use of a broad variety of test, control and data acquisition equipment and software
• Strong ability to work and communicate effectively with team and peers within a manufacturing and engineering organization. This includes excellent communication skills: written and verbal, is a plus
• 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 as a means to enable an engineering organization to achieve outstanding quality, reliability and excellence

Compensation and Benefits
Benefits

Along with competitive pay, as a full-time Tesla employee, you are eligible for the following benefits at day 1 of hire:

• Aetna PPO and HSA plans > 2 medical 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 Account) HSA Contribution when enrolled in the High Deductible Aetna medical plan with HSA
• Healthcare and Dependent Care Flexible Spending Accounts (FSA)
• LGBTQ+ care concierge services
• 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
• Employee Assistance Program
• Sick and Vacation time (Flex time for salary 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