Manufacturing Process Tooling Engineer - Optimus Machining

Job Description

<p>Tesla is seeking a Manufacturing Process Tooling Engineer to support the development and launch of the Optimus Gears manufacturing program. This role owns development, optimization, and sustaining of specialized tooling and process systems that enable precision gear production — transitioning automated lines from early prototypes through FAT/SAT commissioning to mass production (SOP). </p><p>APPLICATION NOTE: You do not need expertise in all areas to apply. We are looking for specialized engineering depth. The successful candidate will own and lead process/tooling development for ANY ONE of the following technical tracks: </p><ul class="tds-list tds-list--unordered"><li><b>Track 1: Precision Machining and Grinding — </b>process ownership for high-precision machining and grinding operations supporting Optimus gears </li></ul><ul class="tds-list tds-list--unordered"><li><b>Track 2: Cutting Tool Design and Fabrication — </b>design and manufacture of cutting tools for precision gear production </li></ul><ul class="tds-list tds-list--unordered"><li><b>Track 3: Complete Tool Management Life Cycle — </b>end-to-end tool management systems, presetting, regrind/re-tip workflows, and CNC cell integration </li></ul><ul class="tds-list tds-list--unordered"><li><b>Track 4: Advanced Metrology — </b>CMM programming, inline automated gauging, GD&amp;T, and Gage R&amp;R </li></ul><p>You will partner with Process, Equipment, Mechanical, Electrical, Controls, Project Management, Quality, and Manufacturing stakeholders, and with external suppliers, to specify equipment, validate processes, and drive quality, cycle time, uptime, and cost-per-part targets. The ideal candidate is hands-on, data-driven, and comfortable owning a technical track end-to-end in a fast-paced NPI and ramp environment. </p><p>Travel expected 25% — ability to travel domestically and internationally to other Tesla factory locations and suppliers as required. </p>

Job Responsibilities

• Fully own, optimize, and scale operational performance of your assigned technical track within Optimus Machining / Gears (precision machining and grinding; cutting tool design and fabrication; complete tool management life cycle; or advanced metrology) 

• Lead cross-functional collaboration across process, equipment, mechanical, electrical, controls, project management, quality, and manufacturing stakeholders; support equipment specifications, supplier RFQs, design reviews, and process validation 

• Design carbide and PCD cutting tools to meet precision gear machining requirements for quality, tool life, and cost 

• Design and develop full turnkey systems for regrinding carbide cutting tools and re-tipping PCD cutting tools 

• Integrate tool management systems into CNC machining cells and drive closed-loop tool life, presetting, and traceability 

• Create and maintain process flows, PFMEA, control plans, standardized work, and related technical documentation for tooling and related processes 

• Support installation, Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), and commissioning of tooling and related equipment 

• Manage large-scale projects for new programs, including timing plans, cost breakdowns for executive approval, risk identification and corrective action, status reporting, and oversight of installation and commissioning 

• Drive continuous improvement of auxiliary and tooling systems to improve quality, reduce cycle time, increase uptime, and lower cost per part, using Design of Experiments (DOE), SPC, and data-driven methods to optimize tooling performance, process capability, and variation 

• Partner on metrology and gauging strategies as applicable to the assigned track, including CMM programming, inline automated gauging, GD&T, and Gage R&R 

Job Requirements

• Degree in Mechanical, Industrial, Manufacturing Engineering, Metrology, or a related field, or equivalent experience 

• Hands-on expertise launching and optimizing equipment or processes within one of the four core tracks (precision machining and grinding, cutting tool design and fabrication, tool management life cycle, or advanced metrology) 

• Experience with CNC programming, process optimization, and cutting tool design 

• Experience with tool management systems, tool pre-setters, and related programming and configuration 

• Strong statistical background with proven application of Design of Experiments (DOE), statistical process control (SPC), and data-driven optimization 

• Knowledge of robotics, automation, and machine vision as they relate to machining cells and tool and process validation 

• Proficiency in CAD (CATIA, SolidWorks, Inventor, and/or AutoCAD) and ability to read and create manufacturing and tooling drawings 

• Familiarity with PFMEA, control plans, standardized work, and Lean manufacturing practices 

• Demonstrated project leadership for equipment or process launches, including timing, cost, risk, and commissioning oversight 

• Strong analytical and problem-solving skills with excellent cross-functional communication under changing priorities; able to work hands-on on the factory floor and support ~25% travel domestically and internationally to suppliers and Tesla sites as required