Process Engineer, Injection Molding

The Plastics Process Engineer will be responsible for the development of plastics manufacturing processes, equipment/tooling alternatives, sequence, and flow of operations for the effective utilization of personnel, material, machines, auxiliary equipment, and facilities necessary to produce parts. Implement, develop, and optimize production methodologies in the manufacturing operations of Tesla Plastics Fremont. 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, quality, and industrial 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.


Responsibilities

• Develop scientific injection molding processes and validate processes to achieve high quality parts
• Comprehensive knowledge of DOE techniques to develop optimized Injection molding processes
• Analyze and optimize production processes to ensure safety while maximizing yield, capacity, and capability in cost effective means while driving to achieve world-class quality levels
• Develop and modify line layouts, including material flow, waste reduction, and ergonomics, utilizing Lean Manufacturing best practices
• Monitor and audit manufacturing processes to ensure product specifications and standards are achieved and maintained. Lead and assist production in all quality and process related topics and issues. Monitor and reduce process variation using Statistical Process Control
• Create and maintain Manufacturing work Instructions, routings, and associated processes
• Participate in the transition of a product from concept to pilot line production and into mass manufacturing
• Apply technical knowledge to innovate, design and develop processes, tooling, assembly fixtures and procedures. Participate in the development and maintenance of FMEAs and Control Plans
• Implement and support Lean manufacturing and 5S initiatives
• Support and assist maintenance team in troubleshooting difficult breakdowns and chronic equipment failures

Requirements

• Bachelor's Degree in Plastics, Mechanical, Manufacturing/Industrial Engineering or with equivalent experience
• Minimally 3 years' experience in fast-paced manufacturing environment preferred
• Must possess process engineering skills (process development/improvement, troubleshooting, data analysis, DOE/constraint analysis, flow optimization, root cause analysis, etc.)
• Strong team working skills at all levels of an organization, especially skilled at working with direct labor to understand challenges and work on developing optimal solutions using structured methods
• Good understanding of BOMs, manufacturability, process design, process validation, assembly methods, design reviews and cost reduction methodologies
• Experience breaking down high-level (e.g. device level) performance issues into addressable action items. Capable of identifying critical process parameters and applying statistics to process measurement and control
• Working knowledge of Mold flow for assisting in developing Injection molding processes, and experience of working with multi-gate hot runner systems is preferred
• Prior EOAT, six axis robot and programming experience preferred
• RJG Master Molder Certification or equivalent, CAD software Solidworks, CATIA etc. preferred
• 20% business travel required

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


Expected Compensation

$76,000 - $240,000/annual salary, depending on level + cash and stock awards + benefits

Pay offered may vary depending on multiple individualized factors, including market location, job-related knowledge, skills, and experience. The total compensation package for this position may also include other elements dependent on the position offered. Details of participation in these benefit plans will be provided if an employee receives an offer of employment.