Tesla Motors, Inc.
Process Engineer, Battery Pack, Megafactory
Tesla Motors, Inc., Nevada, Iowa, United States, 50201
What to Expect
The Process Engineer will be responsible for process sustaining and continuous improvement on the production line, building Tesla's commercial scale energy storage product. This position will be responsible for applying lean manufacturing principles to monitor yield, fallout, and critical parameters and drive necessary process improvements. Daily work will be highly cooperative in nature with regularly interactions with manufacturing engineering, new product introduction, quality engineering, equipment engineering, and production operators - strong interpersonal skills are critical. The engineer will place a significant focus on troubleshooting and root causing test failures and fallout, including data collection and rework process development.
The Process Engineer should be detail focused with an understanding of the big picture. They must be curious, self‑motivated, receptive to feedback, and appreciate an environment where superior work is encouraged, noticed and rewarded.
This role will be based out of the Greater Houston Area (TX) and will require 90% travel to the Bay Area (CA) to support early builds and validation support for the next 6‑12 months.
What You'll Do
Develop expertise in manufacturing 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
Root Cause analysis of complex systems, and mitigation of failure modes via a systems approach
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 (CIP) to maximize yield, capacity, and capability
Lead continuous improvement activities to drive improvements to critical KPIs: safety, quality, output, and cost. Establish and monitor SPC for all critical process parameters, then analyze, develop, process, and implement Engineering Change Orders
Lead NCM (non‑conforming material) activities, including the documentation and troubleshooting of line fall out. Create troubleshooting guides and document procedures for offline failure analysis of test failures and non‑conformances. Design, validate, and document rework procedures for non‑conforming material
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)
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
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
What You'll Bring
Degree in Mechanical, Electrical, Mechatronics, Robotics Engineering, or equivalent experience
Experienced in programming, troubleshooting, and integrating PLC platforms with ladder logic and structured text
Experience commissioning and optimizing equipment. Have a demonstrated track record of Overall Equipment Effectiveness (OEE) improvement
Robotics maintenance, troubleshooting, optimization & programming, preferred
5+ years in an automated, high volume manufacturing facility
Experienced in safety control devices and safety logic is preferred
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, preferred
Able to read and interpret basic mechanical drawings and electrical schematics, experience developing and improving HMI's, Fanuc Robotics / Ignition Experience, preferred
Experience with Dispense systems, Vision (Keyence or Cognex), Laser welding and Fastening (Atlas Copco) preferred
Strong SQL skills and ability to create interactive dashboards using data visualization tools like Power BI or Tableau preferred
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)
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
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The Process Engineer should be detail focused with an understanding of the big picture. They must be curious, self‑motivated, receptive to feedback, and appreciate an environment where superior work is encouraged, noticed and rewarded.
This role will be based out of the Greater Houston Area (TX) and will require 90% travel to the Bay Area (CA) to support early builds and validation support for the next 6‑12 months.
What You'll Do
Develop expertise in manufacturing 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
Root Cause analysis of complex systems, and mitigation of failure modes via a systems approach
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 (CIP) to maximize yield, capacity, and capability
Lead continuous improvement activities to drive improvements to critical KPIs: safety, quality, output, and cost. Establish and monitor SPC for all critical process parameters, then analyze, develop, process, and implement Engineering Change Orders
Lead NCM (non‑conforming material) activities, including the documentation and troubleshooting of line fall out. Create troubleshooting guides and document procedures for offline failure analysis of test failures and non‑conformances. Design, validate, and document rework procedures for non‑conforming material
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)
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
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
What You'll Bring
Degree in Mechanical, Electrical, Mechatronics, Robotics Engineering, or equivalent experience
Experienced in programming, troubleshooting, and integrating PLC platforms with ladder logic and structured text
Experience commissioning and optimizing equipment. Have a demonstrated track record of Overall Equipment Effectiveness (OEE) improvement
Robotics maintenance, troubleshooting, optimization & programming, preferred
5+ years in an automated, high volume manufacturing facility
Experienced in safety control devices and safety logic is preferred
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, preferred
Able to read and interpret basic mechanical drawings and electrical schematics, experience developing and improving HMI's, Fanuc Robotics / Ignition Experience, preferred
Experience with Dispense systems, Vision (Keyence or Cognex), Laser welding and Fastening (Atlas Copco) preferred
Strong SQL skills and ability to create interactive dashboards using data visualization tools like Power BI or Tableau preferred
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)
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
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