Tesla

Makes electric cars, robotaxis and grid batteries

Senior Manufacturing Process Engineer - Robotics

Manufacturing EngineeringConfirmed live in the last 24 hours

Full-timeAustin, TX, USANo salary listed

About the Job

Requirements

A degree in Mechanical Engineering, Manufacturing Engineering, or equivalent experience.
At least 5 years of manufacturing process engineering experience in high-volume production environments; automotive, electric motors, precision metal stamping, or electrical steel/component manufacturing experience is preferred. Senior-level ownership of process development and industrialization is expected.
Expertise in high-speed stamping and metal forming for motor laminations or similar precision components, including progressive or compound die design and operation, press setup and controls (mechanical, hydraulic, or servo), coil feeding, and electrical-steel material science, including silicon content, coatings, magnetic properties, grain orientation, and processing effects.
Proficiency with CAD/CAM software such as SolidWorks or AutoCAD, die design and review, stamping process simulation, PLCs, robotics, vision systems for quality inspection, and industrial communication protocols such as EtherCAT and Profinet.
Ability to perform data analysis, statistical process control, root-cause analysis, and continuous improvement using Lean Manufacturing, Six Sigma, DOE, and tools such as Minitab or equivalent.
Strong problem-solving skills and a hands-on approach to debugging complex process and equipment issues in a production setting.
Ability to work in a fast-paced, dynamic environment, with occasional overtime or shift work to support 24/7 manufacturing.
Ability to travel as required for equipment or die supplier visits, trials, or buyoffs (>5%).

Responsibilities

Develop, qualify, and optimize high-speed stamping processes using progressive, compound, or hybrid dies for electric motor laminations made from electrical steel coil, ensuring precise geometry, flatness, edge quality, and coating integrity to maximize motor efficiency and minimize core losses.
Specify, design or review, validate, and industrialize dies, tooling, press parameters, lubrication, strip feeding, and material-handling systems tailored to electrical steels, including silicon steels and advanced grades.
Integrate and optimize automation elements, including robotics, PLCs, sensors, vision systems, servo or VFD controls, and end-of-line stacking or bonding equipment, to achieve high throughput, consistent quality inspection, and automated lamination stacking or interlocking.
Troubleshoot process, tooling, press, and automation issues on the production floor; lead root-cause analysis and implement permanent corrective actions to minimize downtime and scrap.
Partner with product design, die engineering, tooling suppliers, quality, and maintenance teams on Design for Manufacturability, Design for Assembly, equipment validation (IQ/OQ/PQ), process capability (Cpk), and industrialization of new motor designs and production lines.
Drive continuous improvement initiatives using Lean Manufacturing, Six Sigma, and advanced methods such as predictive maintenance, energy-efficient press operation, electrical-steel scrap reduction and recycling, and waste minimization, aligned with sustainability goals.
Support new product introduction and production ramp-up by transferring processes into manufacturing, training operators and technicians, and ensuring robust, scalable workflows.
Ensure compliance with safety standards, including safety PLCs and fail-safe systems, quality systems, regulatory requirements, and environmental goals throughout the process and equipment lifecycle.

Desired Qualifications

Experience in automotive, electric motors, precision metal stamping, or electrical steel/component manufacturing.
Six Sigma Green Belt or Black Belt certification.
Knowledge of secondary lamination processes such as stacking, interlocking, bonding, and welding, and quality metrology including dimensional, optical, and coating evaluation, and ideally magnetic-property evaluation.

Category	Manufacturing
Location	AUSTIN, Texas
Requisition ID	276835
Type	Full-time

Job Description

<p>The Sr. Manufacturing Process Engineer, Robotics, leads process design and industrialization efforts that deliver exceptional product quality and volumes for next-generation electric motors manufacturing. You will collaborate closely with cross-functional teams—including design engineering, die engineering, tooling suppliers, quality, automation, and operations—to improve throughput, reduce scrap and downtime, and ensure processes meet Tesla’s rigorous standards for performance, safety, and sustainability. This position blends advanced stamping expertise, materials science for electrical steels, tooling/process optimization, automation integration, and data-driven continuous improvement in a fast-paced, high-volume manufacturing environment.</p>

Job Responsibilities

Develop, qualify, and optimize high-speed stamping processes (progressive, compound, or hybrid dies) for electric motor laminations from electrical steel coil, ensuring precise geometry, flatness, edge quality, and coating integrity to maximize motor efficiency and minimize core losses
Specify, design/review, validate, and industrialize dies, tooling, press parameters, lubrication, strip feeding, and material handling systems tailored to electrical steels (silicon steels and advanced grades)
Integrate and optimize automation elements—including robotics, PLCs, sensors, vision systems, servo/VFD controls, and end-of-line stacking/bonding equipment—to achieve high throughput, consistent quality inspection, and automated lamination stacking or interlocking
Troubleshoot process, tooling, press, and automation issues on the production floor; lead root-cause analysis (RCA) and implement permanent corrective actions to minimize downtime and scrap
Partner with product design, die engineering, tooling suppliers, quality, and maintenance teams on Design for Manufacturability (DFM), Design for Assembly (DFA), equipment validation (IQ/OQ/PQ), process capability (Cpk), and industrialization of new motor designs and production lines
Drive continuous improvement initiatives using Lean Manufacturing, Six Sigma, and advanced methods—such as predictive maintenance, energy-efficient press operation, scrap reduction/recycling of electrical steel, and waste minimization—aligned with Tesla’s sustainability goals
Support new product introduction (NPI) and production ramp-up by transferring processes into manufacturing, training operators/technicians, and ensuring robust, scalable workflows
Ensure full compliance with safety standards (including safety PLCs and fail-safe systems), quality systems, regulatory requirements, and environmental goals throughout process and equipment lifecycle

Job Requirements

Degree in Mechanical Engineering, Manufacturing Engineering, or equivalent experience
5+ years of experience in manufacturing process engineering within high-volume production environments, preferably automotive, electric motors, precision metal stamping, or electrical steel/component manufacturing. Senior-level ownership of process development and industrialization is expected
Proven expertise in high-speed stamping and metal forming processes for motor laminations or similar precision components, including progressive/compound die design and operation, press setup/controls (mechanical, hydraulic, or servo), coil feeding, and material science of electrical steels (e.g., silicon content, coatings, magnetic properties, grain orientation, and processing effects)
Strong proficiency with process and tooling tools/software: CAD/CAM (SolidWorks, AutoCAD, or equivalent), die design/review, stamping process simulation, PLCs (Allen-Bradley, Siemens, etc.), robotics (Fanuc, KUKA, or similar), vision systems for quality inspection, and industrial communication protocols (EtherCAT, Profinet, etc.)
Demonstrated ability to perform data analysis, statistical process control, root-cause analysis, and continuous improvement using Lean Manufacturing, Six Sigma (Green/Black Belt preferred), DOE, and tools such as Minitab or equivalent
Knowledge of secondary lamination processes (stacking, interlocking, bonding, welding) and quality metrology (dimensional, optical, coating, and ideally magnetic property evaluation) is highly desirable
Excellent problem-solving skills with a hands-on approach to debugging complex process and equipment issues in a production setting
Ability to work in a fast-paced, dynamic environment with occasional overtime or shift work to support 24/7 manufacturing
Travel as required for equipment/die supplier visits, trials or buyoffs (>5%)

About the Company

Tesla

Makes electric cars, robotaxis and grid batteries

Tesla makes electric cars and batteries that store power for homes and utilities, and it develops self-driving software and humanoid robots. In 2023, its Model Y became the first electric vehicle to rank as the world's best-selling car. Buyers order the Model 3 sedan, Model Y SUV, or Cybertruck pickup directly from Tesla instead of through dealers, and they charge on its Supercharger fast-charging network. It also sells Megapack and Powerwall batteries, runs a robotaxi service, and charges drivers a monthly fee for self-driving software that still needs their supervision. Tesla was founded in 2003, with Elon Musk as its lead early investor and a recognized co-founder, and it is based in Austin, Texas.

Company size: 10,001+
Company stage: IPO
Headquarters: Austin, TX
Founded: 2003

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