Sr. Process Engineer, Body in White, Semi

A Process Engineer will implement, develop, and optimize production methodologies in the Body in White manufacturing operations of Tesla. This Engineer will be responsible for OEE and drive process optimization that may include tool/fixture selection, line layouts, ergonomicstudy, 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 production lines with cost reduction and yield improvements.


Responsibilities

• Develop production lines from pilot stage to full scale production working with vendors and manufacturing engineering to transfer knowledge for sustaining the production lines
• Perform process analysis, DOE (design of experiments), PFMEA, line balancing activities, and capacity modeling. Provide DFM (design for manufacturability) input to design team for process and yield improvements
• Develop and modify line and workstation layouts, including material flow, waste reduction, and ergonomics, 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 (CIP) to maximize yield, capacity, and 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)
• 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

• Bachelor's Degree in Engineering, Mathematics, Physical Science or other applicable degree (advanced degree preferred) or equivalent experience
• Experience leading large projects with direct or in-direct reports in a manufacturing setting and 5+ years working in a body in white manufacturing environment
• Experience with MIG & spot welding, bolting, and riveting joints
• Experience developing and improving process. 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 analysis experience using tools like MySQL, Python, R, JMP, Minitab. Ability to develop data driven root cause analyses and solutions
• 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 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

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