Process Engineer, Remanufacturing

Description:
The GFTX Remanufacturing organization is seeking a Process Engineer to implement, develop, and optimize production methodologies for HV batteries remanufacturing operations. This role focuses on driving process improvements, reducing waste, and ensuring alignment with remanufacturing goals. The engineer will lead cross-functional initiatives and collaborate with external vendors to commission new automated systems. They will interface with NPI, Design, Test, Quality, and Service Engineering to solve complex problems, improve manufacturability, and sustain products through cost reduction and yield improvements. The role requires a self-starter who thrives in ambiguous environments, takes initiative, and delivers results with minimal oversight.

Responsibilities:
Lead cross-functional teams in developing process flows, control plans, work instructions, process capability analyses, rework procedures, and calibration/qualification of tools
Analyze and optimize production processes to ensure safety, maximize OEE, and achieve world-class quality levels. Champion continuous improvement projects to improve yield, capacity, and cost
Work closely with maintenance and equipment engineering on a daily basis to troubleshoot equipment issues and address production issues
Lead NCM (non-conforming material) activities including troubleshooting documentation, line fall-out analysis, and offline failure procedures for test failures and non-conformances
Monitor and reduce process variation using SPC and MSA. Audit manufacturing processes to ensure compliance with product specifications and standards
Develop expertise in remanufacturing processes, analyzing critical data to understand process capabilities and optimize line layouts, material flow, waste reduction, and ergonomics using Lean Manufacturing Principals
Analyze data from multiple sources to identify trends in build quality and efficiency, developing robust data collection, visualization, and analysis tools. Enable data-driven decisions using software like MySQL, Python, R, JMP, Minitab, Tableau, and Ignition
Participate in the transition of products from concept to pilot line production and into mass manufacturing, developing documentation and creating reliable systems
Participate in the development and maintenance of FMEAs and control plans. Analyze, develop, and implement Engineering Change Orders (ECOs). Integrate and sustain MES (Manufacturing Execution Systems) for areas of ownership to enhance traceability and performance
Proactively identify opportunities to improve remanufacturing processes, taking initiative to resolve challenges in ambiguous environments

Requirements:
3+ years of experience working on processes within high-volume automation and/or electromechanical production systems. Degree in Engineering or equivalent relevant experience
Demonstrated experience in developing and improving processes, with a track record of OEE improvement activities
Strong understanding of BOM, MES, Specification Management, and Change Point Management
Strong problem-solving skills and aptitude for learning systems quickly. Experience with structured problem-solving techniques (e.g., DMAIC, Ishikawa, Five Why, 8D)
Exceptional ability to manage simultaneous activities, competing priorities, and challenges. Strong communication skills (written and verbal) for collaboration within manufacturing and engineering teams
Creative mindset to develop innovative, cost-effective solutions that align with Tesla’s approach to revolutionary product development
Passion for delivering high-quality products through testing and continuous improvement
Experience with imaging, vision systems, laser processes, or laser welding is a plus
Familiarity with power electronics, electrical measurements, testing, and metrology systems is a plus
A self-starter who thrives in ambiguous environments, takes initiative, and delivers results with minimal supervision

Compensation & Benefits:
Benefits

Along with competitive pay, as a full-time Tesla employee, you are eligible for the following benefits at day 1 of hire:
Medical plans > plan options with $0 payroll deduction
Family-building, fertility, adoption and surrogacy benefits
Dental (including orthodontic coverage) and vision plans, both have options with a $0 paycheck contribution
Company Paid (Health Savings Accounts) HSA Contribution when enrolled in the High-Deductible medical plan with HSA
Healthcare and Dependent Care Flexible Spending Accounts (FSA)
401(k) with employer match, Employee Stock Purchase Plans, and other financial benefits
Company paid Basic Life, AD&D
Short-term and long-term disability insurance (90 day waiting period)
Employee Assistance Program
Sick and Vacation time (Flex time for salary positions, Accrued hours for Hourly positions), and Paid Holidays
Back-up childcare and parenting support resources
Voluntary benefits to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance
Weight Loss and Tobacco Cessation Programs
Tesla Babies program
Commuter benefits
Employee discounts and perks program