Process Safety Engineer - Terafab

Job Description

We are building Terafab, a vertically integrated semiconductor factory at an unprecedented scale. The facility houses logic, memory, packaging, test, and lithography mask production under one roof, optimized for rapid iteration and maximum compute density per square foot. 

Tesla is seeking a Process Safety Engineer to own and drive process safety programs for the Austin Fab. You will identify, assess, and mitigate process safety hazards tied to advanced dielectric deposition, etch, metallization, and other critical process technologies including safe handling of pyrophoric, toxic, and reactive chemicals and gases while supporting performance, yield, and integration goals. You will partner closely with process, equipment, integration, facilities, and operations across deposition, etch, clean, CMP, photo, metrology, and thermal processing.  

Job Responsibilities

• Facilitate risk assessments including HAZID, HAZOP, LOPA, FMEA, DHA, and Offsite Consequence Analysis (OCA) for pyrophoric, toxic, and corrosive materials common in semiconductor manufacturing; drive clear, actionable risk mitigation 

• Own compliance with Process Safety Management (PSM), Risk Management Program (RMP), SEMI standards, and Tesla EHS policies for hazardous gases, chemicals, and wafer fab processes 

• Lead design reviews for fab tools (e.g., CVD, etch, CMP, diffusion, lithography), utility systems, and high-purity chemical processes to embed safety and reliability in cleanroom environments 

• Perform process safety calculations for emergency relief systems, toxic gas dispersion, flammability analysis, Electrical Area Classification (EAC), and vent abatement specific to semiconductor process gases and liquids 

• Partner with process, mechanical, and facilities engineering to implement engineering controls and safe work practices for identified fab hazards 

• Support fab startup, Pre-Startup Safety Reviews (PSSR), tool commissioning, and qualification — solving problems early so ramp stays aggressive and operations stay safe and compliant 

• Lead and support EHS audits, incident investigations, and site Management of Change (MOC) to sustain process safety excellence in high-volume manufacturing 

Job Requirements

• Degree in Chemical Engineering, Process Safety, or a closely related engineering field; or equivalent experience

• 5+ years in process safety, preferably in semiconductor fabrication or a similarly complex chemical/process manufacturing environment 

• Demonstrated experience leading or facilitating PHAs, HAZOPs, DHAs, and related risk assessments 

• Working knowledge of OSHA PSM, EPA RMP, and applicable state agency requirements 

• Ability to read and interpret P&IDs, PFDs, architectural permit sets, and CAD drawings 

• Experience translating local, state, and federal process safety and EHS requirements into practical design and operating guidance 

• Proven ability to manage multiple projects with competing priorities and mixed near-term and long-horizon deliverables in a fast-paced environment