Sr. Process Engineer

Job Description

Tesla is seeking a highly motivated and experienced Senior Process Engineer to join our Body in White (BIW) team at Gigafactory New York. As a Senior Process Engineer, you will play a critical role in maintaining and improving existing processes, tooling, and automated robotic systems, as well as collaborating with cross-functional teams to resolve production bottlenecks and improve line performance.  This role will support the production of Energy Storage products and Tesla Superchargers.

Job Responsibilities

• Serve as a subject matter expert in MIG welding, resistance spot welding, and structural adhesive processes
• Perform Root Cause analysis of complex systems and mitigation of failure modes
• Lead production trials to optimize sub-systems and introduce new product designs
• Analyze production processes to ensure safety while maximizing Overall Equipment Effectiveness
• Lead non-conforming material (NCM) activities, including the documentation of rework procedures and troubleshooting of line fall out
• Utilize structured problem-solving techniques such as DMAIC, Ishikawa, Five Why (5W) and Eight Disciplines (8D). Perform supporting activities for manufacturing such as 5S and Lean initiatives, material handling improvements, and production line layout changes
• Monitor and reduce process variation using techniques such as Statistical Process Control (SPC) and Measurement Systems Analysis (MSA)
• Create and maintain manufacturing instructions, SCADA displays, operational dashboards, and associated processes
• Develop process sheets, PFMEAs, control plans, standard operating procedures, analyze and improve cycle time, balance workloads, and reduce bottlenecks
• Implement poke-yoke, process audits, root cause analysis for welding defects (e.g., porosity, undercuts)

Job Requirements

• Degree in Mechanical Engineering, Mechatronics, Automotive Engineering, Structural Engineering, or equivalent experience
• Background in Geometric Dimensioning and Tolerancing (GD&T)
• 6+ years of experience developing and improving high volume manufacturing processes. At least 2 years of experience in spot welding, MIG welding, or other joining methods
• Ability to initiate design changes using the following principles: Design for Manufacturability, Poka Yoke, and elimination of failure modes
• Strong understanding of Bill of Materials, Manufacturing Execution System, Quality Specifications, Process Capability (Cpk), and Change Management
• Ability to utilize structured problem-solving techniques such as DMAIC, Ishikawa, Five Why (5W) or Eight Disciplines (8D)
• Excellent communication skills - written and verbal
• Ability to collaborate with cross-functional teams to solve highly technical problems
• Linux, Tableau, SQL, Ignition and/or Minitab experience preferred
• Fanuc robots and PLC programming experience preferred