Sr. Process Engineer, New Cell Technologies

As a Sr. Process Engineer, you will play a critical role in the development, scaling, and optimization of high-volume cell manufacturing processes for Tesla's next-generation energy products. You will be at the forefront of cutting-edge and pioneering cell technologies, driving innovation from concept to mass production. Lead the design, implementation, and continuous improvement of advanced manufacturing processes for new and existing battery cell technologies. Spearhead initiatives related to new product introduction and process engineering, focusing on world-class production efficiency, cost, and quality. Develop optimized product flows through data-driven process design, including fixture/tooling selection, line layout optimization, ergonomic assessments, material presentation strategies, 5S, Kaizen, Gemba walks, and Six Sigma methodologies. Collaborate with cross-functional teams including design, quality, test, and NPI to improve manufacturability, solve complex production challenges, and support the launch of innovative cell designs. Partner with OEM for the specification, installation, and commissioning of state-of-the-art automated manufacturing lines. Mentor and guide junior engineers, fostering a culture of engineering excellence and technical depth. Work with Quality Engineering to analyze production data and establish robust process controls and material specifications to ensure reliability and scalability.

Responsibilities

• Lead cross functional teams in the development of process flows, control plan, GR&R, work instructions, process capability, rework procedures, calibration and qualification of tools, quality validation, risk assessments (PFMEA) & new product introduction
• Collaborate with original equipment manufacturers in the commissioning and start of production of new automated manufacturing equipment. Collaborate with EHS in the identification, prevention, and mitigation of safety hazards, proposing and implementing engineering solutions
• Create and implement mentorship programs for Jr. Engineers, emphasizing product knowledge and process initiation
• Develop expertise in manufacturing processes. Understand process capabilities through critical data analysis and in depth understanding of the product. Develop and modify line layouts, including material flow, waste reduction, and ergonomics, utilizing Lean Manufacturing best practices. Participate in the transition of a product from concept to pilot line production and into mass manufacturing, developing documentation and creating reliable systems
• Analyze and optimize production processes to ensure safety while maximizing Overall Equipment Effectiveness (OEE) in cost effective means while driving to achieve world-class quality levels. Champion continuous improvement projects (CIP) to maximize yield, capacity, and capability
• Lead engineering teams to execute complex projects while maintaining clear communication channels and detailed reporting to senior management
• Lead cross functional collaboration efforts in the identification, improvement, and mitigation of KPI indicator such as scrap and product cost
• Analyze data from various sources to identify trends in build quality and efficiency. Develop robust and clear data collection, visualization, and analysis tools. Enable data driven operational and financial decisions through predictive insights into tool and process performance, including integration of factory data systems and use of software such as MySQL, Python, R, JMP, Minitab, Tableau and Ignition
• Monitor and reduce process variation using techniques such as Statistical Process Control (SPC) and Measurement Systems Analysis (MSA). Monitor and audit manufacturing processes to ensure product specifications and standards are achieved. Participate in the development and maintenance of FMEAs and control plans. Analyze, develop, process, and implement Engineering Change Orders. Integrate and sustain MES (Manufacturing Execution Systems) for area of ownership to enhance traceability and manufacturing performance
• Support 24 by 7 production operations

Requirements

• 6+ years working on processes within high volume automation and/or electro-mechanical production systems
• Degree in Engineering, or equivalent relevant experience
• Good understanding of bill of materials, manufacturing execution system, specification management, change point management
• Data collection and analysis experience. Ability to develop data driven root cause analyses and solutions
• Strong problem-solving skills and an aptitude for learning systems quickly. Able to utilize structured problem-solving techniques such as DMAIC, Ishikawa, Five Why (5W) or Eight Disciplines (8D). Able to resolve high level performance issues into addressable actions
• Exceptional capacity for managing simultaneous activities, competing priorities and challenges. Strong ability to work and communicate effectively with team and peers within a manufacturing and engineering organization. This includes excellent communication skills: written and verbal
• Creative capacity for developing new ways to do things better, cheaper, faster in alignment with the Tesla approach to revolutionary product development
• Passion for making fantastic new products and using testing as a means to enable an engineering organization to achieve outstanding quality, reliability and excellence
• Experience on winding systems, industrial roll to roll or web handling or similar is a plus. Experience on X-ray imaging, vision systems, laser process, laser welding or similar is a plus.
• Overall experience on power electronics, electrical measurements, testing and metrology systems, is a plus