Manufacturing Process Engineer - Optimus Machining

Job Description

<p>Tesla is seeking a Manufacturing Process Engineer to support the development and launch of the Optimus Gears manufacturing program. This role is responsible for developing, optimizing, and sustaining specialized manufacturing processes that enable precision gear production — transitioning automated lines from early prototypes through FAT/SAT commissioning to mass production (SOP) at safety, rate, quality, and cost targets. </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 development for ANY ONE of the following technical tracks: </p><ul class="tds-list tds-list--unordered"><li><b>Track 1: Precision Machining — </b>process ownership for precision machining operations supporting Optimus gears </li></ul><ul class="tds-list tds-list--unordered"><li><b>Track 2: PFMEA, Control Plans, and Standardized Work — </b>process documentation, risk analysis, and manufacturing discipline </li></ul><ul class="tds-list tds-list--unordered"><li><b>Track 3: End-of-Line (EOL) Testing — </b>EOL test development, troubleshooting, and yield improvement </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 Equipment, Mechanical, Electrical, Controls, Project Management, Quality, and Manufacturing stakeholders to specify equipment, validate process capability, run DOEs, and drive OEE and yield. The ideal candidate is hands-on, data-driven, and comfortable owning a technical track end-to-end through launch and ramp in a fast-paced NPI 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; PFMEA, control plans, and standardized work; EOL testing; or advanced metrology), including station- and process-level metrics during pilot builds and production ramp 

• 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 

• Structure, execute, and analyze formal Design of Experiments (DOE) to identify critical process parameters, minimize variation, and establish optimized baselines for complex mechatronic and precision gear components 

• Create and maintain process flows, PFMEA, control plans, standardized work, manufacturing instructions, validation and ramp reports, and training materials required for manufacturing readiness and ownership at SOP 

• Support installation, Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), and commissioning; manage large-scale new-program projects including timing plans, cost breakdowns for executive approval, risk identification and corrective action, status reporting, and commissioning oversight 

• Develop process capability targets and manufacturing acceptance criteria; monitor Cpk/Ppk and drive corrective action where processes are not capable 

• Improve safety, quality, throughput, cycle time, availability, uptime, OEE, and cost per part through continuous improvement of existing processes and auxiliary systems 

• Lead root-cause optimization of equipment failure modes, process bottlenecks, and quality variances using first-principles engineering and data-driven problem-solving, including EOL test development, troubleshooting, and yield improvement as applicable to the assigned track 

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

• Support flexible hours on the factory floor during launch, ramp, and critical quality or yield events as business needs require 

Job Requirements

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

• Hands-on expertise launching and optimizing processes or equipment within one of the four core tracks (precision machining; PFMEA, control plans, and standardized work; EOL testing; or advanced metrology) 

• Experience with CNC programming, process optimization, and precision machining process fundamentals 

• Strong statistical background with proven application of Design of Experiments (DOE), statistical process control (SPC), process capability (Cpk/Ppk), Lean manufacturing, and data-driven optimization 

• Experience creating and sustaining PFMEA, control plans, and standardized work 

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

• Proficiency in CAD (CATIA, SolidWorks, Inventor, and/or AutoCAD) and ability to read mechanical drawings and process documentation 

• Demonstrated track record improving OEE, uptime, cycle time, yield, or process capability using structured problem-solving (e.g., 5-Why, 8D, DMAIC, Pareto) 

• 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