Sustaining Reliability Engineer - Low Voltage Systems

Job Description

<p>We are looking for a Sustaining Reliability Engineer, Low-voltage (LV) electronics with background in LV electronics modules and components. In this role, you will be at the forefront of our commitment to quality and reliability, executing a range of responsibilities that directly&nbsp;impact&nbsp;our products' performance and customer satisfaction. As a successful candidate, you will&nbsp;be responsible for&nbsp;identifying&nbsp;risks and designing and implementing mitigation strategies associated with the manufacturing of our products, from mass production through the hands of our customers.&nbsp;Beyond traditional reliability engineering, this role also&nbsp;draws on&nbsp;data and light analytics to help detect and&nbsp;anticipate&nbsp;failures before they reach the field.&nbsp;</p><p>This role is highly&nbsp;engaging,&nbsp;and you will work with various internal and external cross-functional teams and management. You will oversee validation testing and convey the results to all involved teams. You will play a pivotal part in transitioning from New Product Introduction (NPI) to mass production while also enhancing our technology and volume scaling partnerships by cultivating and&nbsp;validating&nbsp;capable suppliers. You will develop and implement targeted validation plans and procedures for internal manufacturing teams as well as external suppliers to provide early detection of reliability issues during mass production. You will assess manufacturing changes and risks, develop test plans to&nbsp;validate&nbsp;them, and oversee root cause analysis for failures&nbsp;identified&nbsp;in tests.&nbsp; You must have a genuine passion for engineering products that will fundamentally change the world, and you must be self-motivated with the desire to push boundaries. If you have a strong technical first-principles understanding, excellent problem-solving skills, and a genuine fascination for engineering, this is an exciting opportunity to contribute to the&nbsp;cutting-edge&nbsp;technology of Tesla's products and shape the future. It comes natural to you to deliver results under high pressure with tight schedules.&nbsp; The level of this position will be&nbsp;determined&nbsp;at the time of the interview.&nbsp; </p>

Job Responsibilities

• Mitigate manufacturing risks and ensure product reliability during scaling, ramping, and high-volume production across global factories 
• Oversee production validation, early-life reliability monitoring, supplier qualification, and smooth NPI-to-mass production transitions
• Apply expertise in reliability methods and low-voltage electronics to develop accelerated test plans for sustaining activities, including burn-in, ESS, ORT, and reliability growth demonstration
• Generate validation test plans for manufacturing, process, or supplier changes (internal/external), and drive root cause corrective actions
• Collaborate with quality, service, supplier, and design teams to conduct failure analysis and resolve testing/field failures; cascade reliability risks from design DFMEA into process PFMEA and control plans
• Analyze field usage, environmental conditions, and reliability metrics to optimize test methods and requirements for ongoing production
• Provide reliability guidelines, apply lessons learned, and use statistical methods to enable continuous improvements in manufacturing and early-life performance
• Work closely with Field Reliability Teams to identify and drive mitigation for field excursions related to manufacturing deviations, maintaining a closed loop with the New Product Introduction (NPI) reliability teams so field issues are consistently captured and actioned
• Pull together vehicle fault signals and environmental stress data (e.g., temperature, memory usage) and use light analysis to surface fleet risk and anticipate low-voltage failures
• Maintain stakeholder-facing dashboards that combine these insights with Jira issues and reliability test results (validation, ESS, ORT), and use AI/LLM tools to speed up fault diagnosis and root cause analysis
  

Job Requirements

• Degree in Mechanical Engineering, Electrical Engineering, Materials Engineering, Acoustic, or equivalent experience
• 5+ years of experience with low-voltage electronic components/systems and laboratory testing (including relevant internships or academic lab work)
• Understanding of manufacturing processes for electronic components
• Experience with burn-in testing, Environmental Stress Screening (ESS), and Ongoing Reliability Testing (ORT)
• Understanding of highly accelerated testing methods and governing equations for acceleration models (e.g., Arrhenius, Coffin-Manson, inverse power law), and reliability growth modeling
• Experience developing reliability guidelines and innovative testing approaches for sustaining production
• Working knowledge of reliability statistics, including Weibull analysis, and tools like JMP or Minitab, ReliaSoft, MATLAB
• Working knowledge of failure analysis techniques, such as optical microscopy, SEM, CSAM, X-ray, cross-sectioning, and EDX, and root cause analysis methods such as fault tree analysis
• Proven ability to stay engaged, proactive, and positive in challenging situations
• Working knowledge of SQL and Python for data analysis, and comfort using dashboard/visualization tools to share results with stakeholders