Pilot Process Engineer - Model Y, General Assembly

Job Description

<div class="MSWordContent"><p>This Pilot Process Engineer will design, test, implement and optimize new production methodologies and processes for new products and programs in current operation lines in Tesla. This engineer will be responsible for designing the specific production flow for their area requiring direct interface with cross functional teams such as Design, Integration, Equipment, Manufacturing, Quality, Packaging engineering and more. They will introduce new products / program while meeting the critical KPIs of with minimum impact to the pre-existing operations.</div>

Job Responsibilities

• 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
• 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
• Work directly with Design engineering to implement design improvement, before those changes become costly or problematic in the later phases of the engineering design processes
• 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

Job Requirements

• Degree in Engineering or equivalent experience
• Experience developing and improving process by demonstrating a track record of Overall Equipment Effectiveness (OEE) improvement activities
• Strong understanding of Bill of Materials, Manufacturing Execution System, Specification Management, Change Point Management
• Data collection and analysis experience with the ability to develop data driven root cause analyses and solutions
• Strong problem solving skills and an aptitude for learning systems quickly by utilizing structured problem solving techniques such as DMAIC, Ishikawa, FiveWhy (5W) or Eight Disciplines (8D)
• Knowledge of Statistical Process Control and its application
• Strong ability to work and communicate effectively with team and peers within a manufacturing and engineering organization
• Creative capacity for developing new ways to do things better, cheaper, faster in alignment with the Tesla approach to revolutionary product development
• Passion for making fantastic new products and using testing as a means to enable an engineering organization to achieve outstanding quality, reliability and excellence
• Enthusiasm for complete and total ownership of the problem solving process and willingness to drive action against issues that may only impact your lines