Process Engineer - Robotics, Optimus Segment Stamping

Job Description

<p>Tesla is seeking a Process Engineer, Robotics to lead process design and industrialization for Optimus Segment Stamping — high-speed stator lamination production supporting next-generation electric motor manufacturing. You will raise throughput, cut scrap and downtime, and hold Tesla standards for performance, safety, quality, and sustainability in high-volume manufacturing.&nbsp;</p><p>The work combines high-speed stamping, electrical-steel materials, tooling and process optimization, automation integration, and data-driven continuous improvement. You will partner with Design Engineering, Die Engineering, tooling suppliers, Quality, Automation, Maintenance, and Operations from process development through NPI, ramp, and sustaining. The ideal candidate is hands-on, materials- and tooling-fluent, and comfortable owning process capability end-to-end on the factory floor.&nbsp;</p><p>Travel expected more than 5% — ability to travel for equipment and die-supplier visits, trials, and buyoffs as required. Occasional overtime or shift support for 24/7 manufacturing may be required.&nbsp;</p>

Job Responsibilities

• Develop, qualify, and optimize high-speed stamping (progressive, compound, or hybrid dies) for motor laminations from electrical steel coil, holding geometry, flatness, edge quality, and coating integrity to raise motor efficiency and cut core losses 

• Specify, design or review, validate, and industrialize dies, tooling, press parameters, lubrication, strip feeding, and material handling for electrical steels, including silicon steels and advanced grades 

• Integrate and optimize robotics, PLCs, sensors, vision systems, servo and VFD controls, and end-of-line stacking or bonding so throughput, inspection, and lamination stacking or interlocking stay consistent 

• Troubleshoot process, tooling, press, and automation issues; lead root-cause analysis and implement permanent corrective actions to cut downtime and scrap; support flexible hours during launch, ramp, and critical quality or scrap events as business needs require 

• Partner with Product Design, Die Engineering, tooling suppliers, Quality, and Maintenance on DFM, DFA, IQ/OQ/PQ, Cpk, and industrialization of new motor designs and lines 

• Drive continuous improvement with Lean Manufacturing and Six Sigma — including predictive maintenance inputs, energy-efficient press operation, electrical-steel scrap reduction and recycling, and waste minimization — and apply SPC, DOE, and data analysis to establish capable processes and reduce variation 

• Support new product introduction and ramp-up by transferring processes into manufacturing, training operators and technicians, and locking in scalable standardized workflows 

• Hold safety standards across the process and equipment lifecycle, including safety PLCs and fail-safe systems, plus quality systems, regulatory requirements, and environmental goals 

• Support secondary lamination processes (stacking, interlocking, bonding, welding) and quality metrology (dimensional, optical, coating, and magnetic property evaluation) as applicable 

• Create and maintain technical documentation required for ownership at SOP (process flows, PFMEA/control plans, standardized work, validation/ramp reports, and training materials) 

Job Requirements

• Degree in Process Engineering, Manufacturing Engineering, Mechanical Engineering, Materials Science, or equivalent experience

• Experience in manufacturing process engineering in high-volume production, preferably automotive, electric motors, precision metal stamping, or electrical-steel and component manufacturing, with ownership of process development and industrialization 

• Proven expertise in high-speed stamping and metal forming for motor laminations or similar precision parts — including progressive and compound die design and operation; press setup and controls (mechanical, hydraulic, or servo); coil feeding; and electrical-steel material science (silicon content, coatings, magnetic properties, grain orientation, and processing effects) 

• Proficiency with CAD/CAM (SolidWorks, AutoCAD, or equivalent), die design and review, stamping simulation, PLCs (Allen-Bradley, Siemens), robotics (Fanuc, KUKA, or similar), vision inspection, and industrial protocols (EtherCAT, PROFINET) 

• Ability to run data analysis, statistical process control, root-cause analysis, and continuous improvement with Lean Manufacturing, Six Sigma (Green or Black Belt preferred), DOE, and tools such as Minitab 

• Knowledge of secondary lamination processes (stacking, interlocking, bonding, welding) and quality metrology (dimensional, optical, coating, and magnetic property evaluation) is highly desirable 

• Hands-on problem-solving skills for debugging complex process and equipment issues in production 

• Strong cross-functional communication skills; able to work effectively with Design, Die Engineering, Automation, Quality, Maintenance, Operations, and suppliers under changing priorities 

• Ability to work in a fast-paced environment, including occasional overtime or shift work supporting 24/7 manufacturing 

• Ability to travel more than 5% for equipment and die-supplier visits, trials, or buyoffs as required