Tesla

Makes electric cars, robotaxis and grid batteries

Senior Advanced Quality Engineer - Cell Global Quality

Quality EngineeringUpdated on Nov 10

Full-timeNo salary listed

About the Job

Requirements

At least 8 years in manufacturing quality, new product introduction quality, Advanced Product Quality Planning, or related engineering in high-volume or high-reliability manufacturing, with hands-on ownership of Advanced Product Quality Planning deliverables on real programs.
A degree in Mechanical Engineering, Manufacturing Engineering, Chemical Engineering, Materials Engineering, Electrical Engineering, Industrial Engineering, Quality Engineering, or equivalent experience.
Demonstrated deep understanding of manufacturing processes, including the ability to walk a production line, explain how processes create variation and defects, and apply that knowledge to failure mode and effects analysis, Control Plans, and validation work.
Deep working knowledge of Advanced Product Quality Planning core tools, including Process Flow, Design Failure Mode and Effects Analysis, Process Failure Mode and Effects Analysis, Control Plan, Measurement System Analysis, Statistical Process Control, and process validation, with demonstrated ability to link them so special and critical characteristics hold up in production.
Experience with validation plans and protocols, including IQ/OQ/PQ, Design Verification Plan, and capability studies, and structured problem-solving methods including 8D, DMAIC, 5-Why, Ishikawa, and Design of Experiments.
Strong interpersonal, verbal, written, and presentation skills, including the ability to communicate across levels and functions and stop a gate when evidence is weak.
Ability to handle multiple priorities, meet deadlines, and perform under high pressure.
Fluency with Microsoft Office programs, including Word, Excel, and PowerPoint.

Responsibilities

Lead Design Failure Mode and Effects Analysis, process flow, Process Failure Mode and Effects Analysis, and Control Plan development for new cell designs, process and equipment introductions, and major changes, performing the analysis and applying deep manufacturing-process understanding rather than merely facilitating a template.
Work on the manufacturing floor, observe processes and builds, identify actual failure modes, and implement controls that match how the production line operates.
Identify special and critical characteristics from first principles of the cell process and flow them into drawings, process parameters, inspections, and reaction plans.
Participate in design reviews and challenge design, process, and equipment decisions using process knowledge, factory data, test results, and field lessons learned. Drive Design for Quality, Design for Manufacturing/Assembly, and error-proofing so failure modes are designed out rather than inspected out.
Write and maintain the chain from Design Failure Mode and Effects Analysis through Process Flow, Process Failure Mode and Effects Analysis, Control Plan, Measurement System Analysis, Statistical Process Control, inspection, and reaction plan. Run studies and verify that the linkage holds in production.
Review existing Failure Mode and Effects Analyses and Control Plans for effectiveness, evaluate detection methods, sample size, frequency, and test method, and mature controls on processes already in production.
Execute process validation (IQ/OQ/PQ or equivalent), Gage Repeatability and Reproducibility / Measurement System Analysis, capability studies, and run-at-rate; confirm controls work under production conditions.
Participate in first builds, trials, and root-cause analysis; contain issues, find root causes, implement corrective controls, and update Failure Mode and Effects Analysis and Control Plans with lessons learned.
Take design and process changes through risk and control work before volume production by rescoring Failure Mode and Effects Analyses, updating Control Plans, and revalidating measurement and process capability.
Work with factory teams to implement solutions on the manufacturing floor and incorporate lessons from factory, pack, vehicle, energy, and field experience into subsequent design and process iterations.

Desired Qualifications

Experience working with lithium-ion cells, or high-reliability products in aerospace, semiconductor, medical, or similar industries.
Familiarity with AIAG, VDA, IATF, AS9145, or AS9100.
Experience with Failure Mode and Effects Analysis / Advanced Product Quality Planning software, Product Lifecycle Management, or Quality Management System tools.

Category	Manufacturing
Location	AUSTIN, Texas
Requisition ID	288418
Type	Full-time

Job Description

<p>Battery Cells are the common denominator for every Tesla product. Our product requirements demand ground-up cell architectures with state-of-the-art performance, manufactured at volumes that are orders of magnitude higher than the products they power. Our environment is fast-paced and incredibly exciting. Tesla moves quickly, so being passionate and self-motivated to push your limits is critical. Our team works alongside engineering groups across various disciplines, requiring strong communication skills and a team-first mentality. You will work alongside seasoned industry experts, high aptitude recent graduates, and people from every stage in between.</p><p>We are seeking an Advanced Quality Engineer to own Advanced Product Quality Planning (APQP) across Tesla Cell Manufacturing. This person will work with every team in Cell to build a source of truth for design reviews, process and equipment launches, special characteristics, control methods, and production readiness. The ideal candidate drives the program rather than auditing it after the fact, is in the room for builds and root-cause work, and demonstrates total ownership of risk mitigation and control. This person is seasoned in manufacturing for high-reliability applications such as Li-ion cells, aerospace, semiconductor, medical, or a similar field.</p>

Job Responsibilities

Lead DFMEA, process flow, PFMEA, and Control Plan development for new cell designs, process and equipment introductions, and major changes. Do the analysis. This role requires a deep understanding of the manufacturing process, not facilitation of a blank template
Work on the manufacturing floor. Walk the process, watch builds, and use that understanding to identify real failure modes and put in controls that match how the line actually runs
Identify special and critical characteristics from first principles of the cell process and flow them into drawings, process parameters, inspections, and reaction plans
Sit in design reviews and challenge design, process, and equipment decisions with process knowledge, factory data, test results, and field lessons learned. Drive Design for Quality, DFM/DFA, and error-proofing so failure modes are designed out, not inspected out
Write and maintain the chain from DFMEA to Process Flow to PFMEA to Control Plan to MSA, SPC, inspection, and reaction plan. Run the studies and prove the linkage holds in production
Review existing FMEAs and Control Plans for effectiveness. Dig into detection methods, sample size, frequency, and test method, and mature the controls on processes already in production
Execute process validation (IQ/OQ/PQ or equivalent), Gage R&R / MSA, capability studies, and run-at-rate. Confirm controls work under production conditions
Be in the room for first builds, trials, and RCA. Contain issues, find root cause, implement corrective controls, and update FMEA and Control Plan with what was learned
Take design and process changes through the risk and control work before they hit volume: re-score FMEAs, update Control Plans, and re-validate measurement and process capability
Work with factory teams to implement solutions on the manufacturing floor. Pull lessons learned from factory, pack, vehicle, energy, and the field into the next design and process iteration

Job Requirements

8+ years in manufacturing quality, NPI quality, APQP, or related engineering in high-volume or high-reliability manufacturing, with hands-on ownership of APQP deliverables on real programs
Degree in Mechanical Engineering, Manufacturing Engineering, Chemical Engineering, Materials Engineering, Electrical Engineering, Industrial Engineering, Quality Engineering, or equivalent experience
Demonstrated deep understanding of manufacturing processes: able to walk a line, explain how the process creates variation and defects, and put that knowledge into FMEA, Control Plan, and validation work
Deep working knowledge of APQP core tools (Process Flow, DFMEA, PFMEA, Control Plan, MSA, SPC, process validation) and proven ability to link them so special and critical characteristics hold up in production. Familiarity with AIAG, VDA, IATF, or AS9145/AS9100 is valued
Experience working with lithium-ion cells, or high-reliability products in aerospace, semiconductor, medical, or similar, is preferred
Experience with validation plans and protocols (IQ/OQ/PQ, DVP, capability studies) and structured problem solving (8D, DMAIC, 5-Why, Ishikawa, DoE)
Strong interpersonal, verbal, written, and presentation skills, with demonstrated ability to communicate across levels and functions and to stop a gate when evidence is weak
Passion for systematic problem-solving. Detail oriented, with the ability to handle multiple priorities, meet deadlines, and perform under high pressure
Fluent with common MS Office programs (Word, Excel, PowerPoint). Experience with FMEA / APQP software, PLM, or QMS tools is a plus
This position can be based out of either Tesla's Fremont or Austin locations. Up to 50% travel is expected

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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