Process Engineer

Description:
The Sustaining Process Engineer’s (Sustaining Powertrain Process Engineer) primary responsibilities are to eliminate waste in the manufacturing process, drive long-term line improvements to yield, cycle time and process capability. In addition, the process engineer will work with a cross-functional team to develop, introduce, and sustain new model/product/material introductions.
They will be responsible for optimizing product flow through the factory through process optimization that may include tool /fixture selection, line layouts, ergonomic study, material presentation, and other relevant factors. They will interface with design, test, manufacturing, and quality engineering to solve problems, improve manufacturability, and implement continual improvement. They will sustain products with cost reduction and yield improvements. In addition, the Process Engineer will work with quality to compile and evaluate data to determine appropriate limits and variables for process or material specifications.

Responsibilities:
Develop expertise in manufacturing processes. Optimize production workstation layouts to enhance product flow, ergonomics, and efficiency while conducting process analysis, DOE, PFMEA, line balancing, and capacity modeling/simulation
Participate in the transition of a product from pilot line production and into mass manufacturing. Initiate and drive strategies to rapidly ramp the quality and rate of newly launched production lines to full capacity with a focus on maintaining the highest of safety standards and customer demand throughout the ramp duration
Champion continuous improvement projects (CIP) to maximize yield, capacity, and capability. Perform process/ quality baseline studies, PFMEAs and root cause analysis to proactively identify and address process/ quality issues
Responsible for diagnosing issues found during the part manufacturing process and drive corrective action back to source including but not limited to SIE/ SQE, resulting in root cause identification and elimination. Utilize structured problem-solving techniques such as DMAIC, Ishikawa, Five Why (5W) and Eight Disciplines (8D) to optimize key production outcomes
As a process equipment owner, responsible for interfacing with various cross functional teams to drive both short term and long term outcomes – such as production, maintenance, design engineering, quality, manufacturing
Synthesize, collate, and analyze data from machine and factory data systems to identify and eliminate bottlenecks, and to reduce operational costs. Use a range of data collection, visualization, and analysis tools to achieve this goal. Enable data driven operational and financial decisions through 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
Utilize a range of optimization and experimentation techniques to validate new parts, new processes, and to challenge existing limitations on high volume production lines
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. Review and provide disposition to non-conforming material and perform mechanical and electrical failure analysis on components and assemblies
Develop and implement process/ quality control strategies, including poka yokes, testing, tooling and inspections
Create and maintain Manufacturing Instructions, routings, and associated processes. Develop, mentor and train sustaining technicians, assist in the training of operators as needed. Manage activities for process sustaining technicians to support day to day coverage of production line, including developing and documenting appropriate rework procedures

Requirements:
Bachelor’s Degree in Mechanical, Manufacturing, Industrial, or Chemical Engineering or other Engineering discipline, or equivalent in experience
Ability to derive data-supported root causes and propose strong countermeasures. Tableau, and/or Minitab experience preferred. Must be able to pull data using efficient SQL queries
Exceptional problem-solving skills and an aptitude for learning systems quickly
Experience developing and improving Process. Have a demonstrated track record of Overall Equipment Effectiveness improvement activities
Exceptional capacity for managing simultaneous activities and challenges
Demonstrated experience in ramping a high volume, automated and semi-automated manufacturing line
Strong ability to work and communicate effectively with team and peers within a manufacturing and engineering organization. This includes excellent written and verbal communication skills
Experience developing and applying lean six sigma methodologies such as: Waste Reduction, Poka-Yoke, SPC, GR&R, DOE
Experience Vision inspection systems preferred, such as Keyence 2D image inspection and profilometry preferred
Ignition Automation, MES and/or Python experience is highly desired

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