Tesla

Makes electric cars, robotaxis and grid batteries

Staff Process Engineer

Process EngineeringUpdated on Nov 10

Full-timeSparks, NV, USANo salary listedIn-person

About the Job

Requirements

Proven track record leading events and delivering measurable financial results in high-volume manufacturing environments; battery, electronics, or remanufacturing experience is a plus.
Expert-level knowledge of lean manufacturing principles, tools, and techniques, including value stream mapping, 5S, total productive maintenance, single-minute exchange of die, Kanban, and just-in-time; Lean Six Sigma Green Belt or Black Belt certification is preferred.
Strong background in core quality tools, including measurement system analysis, process failure mode and effects analysis, statistical process control, control plans, and statistical analysis, and experience with material review board processes, containment strategies, and corrective and preventive action management.
Proficiency in problem-solving methodologies including 8D, A3, DMAIC, root cause analysis, and design of experiments.
Data-driven mindset with proficiency in data analysis, statistical tools, process mapping, visualization techniques, and experience developing key performance indicators, dashboards, and performance tracking systems.
Excellent facilitation and leadership skills with proven ability to lead diverse, cross-functional teams, drive change, influence without authority, and foster a culture of continuous improvement.
Strong communication and presentation skills in English, capable of conveying complex ideas to audiences ranging from frontline operators to executive leadership.
Demonstrated ability to operate effectively in fast-paced, startup-style environments while managing multiple priorities with a hands-on approach and willingness to spend time on the production floor.

Responsibilities

Lead and facilitate events across EFNV and Remanufacturing facilities by designing event scopes, assembling cross-functional teams, and driving rapid improvements in cycle time, quality, cost, and safety.
Coach and develop employees at all levels in methodology, lean tools, and problem-solving techniques, fostering a culture of continuous improvement.
Establish an event calendar, prioritization framework, and tracking systems to align improvement activities with business objectives.
Conduct value stream mapping and lead workshops focused on reducing the eight wastes, implementing lean principles including 5S, visual management, standard work, and poka-yoke.
Drive cycle time reduction initiatives for critical processes, including EMX validation, cell mapper performance, and backend MOS processes.
Lead technical root cause analysis for complex quality and process issues using advanced problem-solving methodologies, including 8D, A3, 5-Why, Fishbone, and design of experiments, and support corrective and preventive action development for critical issues.
Lead cost-saving initiatives and build optimized processes for cost of poor quality tracking, material review board disposition, and escalation procedures to deliver measurable reductions in waste and spending.
Lead and manage engineering projects for test equipment development, validation process improvements, and production line optimization.
Define processes, create standards, and develop comprehensive standard operating procedures for continuous improvement activities, validation protocols, and manufacturing processes.
Build cross-functional alignment across Quality, Production, Process Engineering, Material Planning, Supplier Quality, and Industrialization teams through Q-Team steering and collaboration.

Desired Qualifications

Battery, electronics, or remanufacturing experience.
Lean Six Sigma Green Belt or Black Belt certification.
Project management certification such as PMP or CAPM, or equivalent experience.

Category	Manufacturing
Location	Sparks, Nevada
Requisition ID	282755
Type	Full-time

Job Description

Tesla Energy in Sparks, NV is seeking a highly motivated and results-driven Staff Process Engineer to lead improvement initiatives across Energy Factory Nevada (EFNV) and Remanufacturing facilities. In this role, you will be a proven leader with deep expertise in lean manufacturing, kaizen facilitation, and cross-functional collaboration to drive operational excellence, cost reduction, and quality improvements across multiple production environments. As the Staff Process Engineer, you will design and facilitate rapid improvement workshops, lead cross-functional teams through root cause analysis and countermeasure implementation, and establish standardized continuous improvement processes across diverse production lines including battery cell manufacturing, energy storage systems, and remanufacturing operations. You will deliver measurable results through structured problem-solving, waste elimination, and sustainable process optimization in high-volume manufacturing settings, contributing to Tesla's mission to accelerate the world's transition to sustainable energy.

Job Responsibilities

Lead and facilitate events across EFNV and Remanufacturing facilities, designing event scopes, assembling cross-functional teams, and driving rapid improvements in cycle time, quality, cost, and safety
Coach and develop employees at all levels in methodology, lean tools, and problem-solving techniques, fostering a culture of continuous improvement
Establish event calendar, prioritization framework, and tracking systems to align improvement activities with business objectives
Conduct value stream mapping and lead workshops focused on 8 waste reduction, implementing lean principles including 5S, visual management, standard work, and poka-yoke
Drive cycle time reduction initiatives for critical processes (e.g., EMX validation, cell mapper performance, backend MOS processes)
Lead technical root cause analysis for complex quality and process issues using advanced problem-solving methodologies (8D, A3, 5-Why, Fishbone, DOE) and support CAPA development for critical issues
Lead cost-saving initiatives and build optimized processes for COPQ tracking, MRB disposition, and escalation procedures to deliver measurable reductions in waste and spend
Lead and manage engineering projects for test equipment development, validation process improvements, and production line optimization
Define processes, create standards, and develop comprehensive SOPs for continuous improvement activities, validation protocols, and manufacturing processes
Build cross-functional alignment across Quality, Production, Process Engineering, Material Planning, Supplier Quality, and Industrialization teams through Q-Team steering and collaboration

Job Requirements

Proven track record leading events and delivering measurable financial results in high-volume manufacturing environments; battery, electronics, or remanufacturing experience is a plus
Expert-level knowledge of lean manufacturing principles, tools, and techniques (VSM, 5S, TPM, SMED, Kanban, JIT); Lean Six Sigma certification (Green Belt or Black Belt) is preferred
Strong background in core quality tools (MSA, pFMEA, SPC, control plans, statistical analysis) and experience with MRB processes, containment strategies, and CAPA management
Proficiency in problem-solving methodologies including 8D, A3, DMAIC, root cause analysis, and DOE
Data-driven mindset with proficiency in data analysis, statistical tools, process mapping, visualization techniques, and experience developing KPIs, dashboards, and performance tracking systems
Excellent facilitation and leadership skills with proven ability to lead diverse, cross-functional teams, drive change, influence without authority, and foster a culture of continuous improvement
Strong communication and presentation skills in English, capable of conveying complex ideas to audiences ranging from frontline operators to executive leadership
Demonstrated ability to operate effectively in fast-paced, startup-style environments while managing multiple priorities with a hands-on approach and willingness to spend time on the production floor
Project management certification (PMP, CAPM) or equivalent experience is preferred

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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