Metrology Systems Engineer

Job Description

Tesla is seeking a highly motivated Metrology Engineer to develop and implement cutting-edge inline metrology systems for our advanced battery cell manufacturing lines (powder, film, and electrode processing lines). This role will be instrumental in developing, optimizing, and scaling up metrology tools and methods, working within a cross-functional team to take new battery designs from concept to high-volume production.

The battery cell is a critical component of Tesla vehicles and energy storage systems. This position offers the opportunity to make significant contributions to our products while working in a fast-paced, innovative environment. The ideal candidate is driven, detail-oriented, and ready to push their limits, as they join in a highly motivated and capable team to make unbelievable things into reality.

Job Responsibilities

• Drive the development and deployment of innovative inline manufacturing metrology solutions, transitioning from proof-of-concept (offline/lab equipment) to high-volume production (inline) to enable improved battery processing, performance, quality, and cost
• Drive metrology installation and commissioning on current and new production lines and interact with suppliers
• Conduct hands on experimentation and get hands on with pilot process equipment to improve metrology capabilities and gain a deep understanding of underlying processes. Support process optimization through metrology-driven data analysis and structured experiments
• Define and/or review metrology specifications required for enabling gauge capable metrology tools to support production processes
• Perform gage capability, tool matching, and measurement uncertainty studies for metrology tools. Work collaboratively across teams (equipment, process, quality, production, safety) to resolve challenges in integrating metrology systems into production
• Support metrology measurements for engineering DOEs for process optimization and be able to drive the data-driven experiments/studies to be able to establish the relationship between metrology results and cell performance
• Train technicians on the maintenance and repair of the metrology systems. Be able to review and coordinate field wiring, pneumatic and fluid piping to optimize the integration
• Perform statistical studies, drive advanced statistics, data analysis, interpretation, visualization and presentation of experimental data proficiently to validate metrology performance and impact on the downstream and cell performance
• Conduct structured problem analysis and root cause investigations to improve system reliability and performance. Investigate and resolve problems arising during inline metrology integration into production process to ensure seamless interaction between process and metrology
• Develop documentation to define and standardize metrology processes for engineering, quality, and production teams

Job Requirements

• Degree in Materials Science, Physics, Mechanical Engineering, Electrical Engineering, Mechatronics Engineering, Computer Science, Automation Engineering, or equivalent experience
• Expertise in at least two of the following areas: 1) Metrology system development and fleet management (e.g., semiconductor industry); knowledge of Six Sigma and statistical methodologies (e.g. gauge capability, process capability). 2) At least one material characterization technique (SEM, XRF, ICP, PSA, Microscopy, etc.) with shown ability to troubleshoot at system and module levels to achieve the desired metrology specifications. 3) Optics and optical sensor development working with a broad range of wavelengths from infrared to UV, with simulation experience (e.g. Zemax). 4) Development of X-ray based characterization tools and experimentation/simulation for X-Ray source/detector modification/selection. 5) Image processing, big data, ability to perform advanced data analytics to investigate data quality issues
• Strong foundation in engineering principles and their application to manufacturing equipment/process development
• Familiar with GD&T requirements for equipment design. Familiar with SolidWorks and blueprint interpretation
• Familiar with Six Sigma concepts such as process and gage capability concepts and requirements
• Proficiency with at least one statistical software package (e.g. JMP, Minitab)
• Proficiency with data acquisition (query building), analysis, and visualization (experience with MySQL, Flux, etc.). Programming experience for data processing (Python, Go, etc.). PLC coding experience (Siemens, Beckhoff, Rockwell) is a plus
• Demonstrate excellent documentation and reporting for installations, commissioning, experimentations, etc. Strong communication skills and ability to simplify complicated concepts for non-technical and cross-functional team members. Proven problem-solving skills using structured problem analysis and data-driven root cause analysis and strong statistical background
• Experience in high volume manufacturing involving one or more of these areas is highly desired: Battery cell engineering, battery quality control, dry powder metrology, handling and processing, roll-to-roll film processing and metrology including web path design and optimization, battery manufacturing (li-ion or other chemistry), manufacturing engineering
• Willingness to travel regularly to Reno, NV and San Diego, CA (as much as 50%)