Sr. Manufacturing Engineer, Metal Forming

Description:
Tesla is seeking a highly experienced Sr. Manufacturing Engineer, Metal Forming to join our vehicle manufacturing engineering team at Gigafactory Texas. In this senior role, you will lead the design & optimization of metal forming equipment and processes for high-volume production of vehicle components for models like Model Y, Cybertruck, and future programs. You will drive efficiency, quality, and innovation in press and automation design, installation, commissioning, and collaborate with cross-functional teams to ensure seamless integration of our automated manufacturing lines. This position requires deep expertise in metal forming, simulation tools, and process improvements to support Tesla's mission of accelerating the world's transition to sustainable energy.

Responsibilities:
Design, implement, and improve stamping presses and automation processes for highest safety, quality, and efficiency while reducing overall cost to enable vehicle production at rate
Collaborate with product & die engineering teams on DFM of various components to allow for an efficient manufacturing process
Commission production processes and equipment using factory and site acceptance testing
Define a robust process control plan to enable high level of quality
Support make vs. buy, and ROI analyses as required, while validating external components suppliers using industry standard PPAP methodology
Collaborate with external vendors and internal stakeholders to conduct design reviews of the production equipment throughout the development process
Plan sufficient capacity to meet business targets for production outputAssess and reduce risk in the assembly process using PFMEA methodology

Requirements:
Degree in Mechanical Engineering, Mechatronics Engineering, Industrial Engineering, Electrical Engineering or equivalent experience
4+ years of experience in manufacturing engineering, with a focus on stamping equipment in high-volume environments (e.g. automotive or aerospace)
4+ years of experience in stamping press operations, including equipment design, hydraulic/servo systems, and material handling for metals like aluminum and steel
4+ years of experience with engineering tools and software, such as CAD (e.g., SolidWorks, AutoCAD), simulation software (e.g., AutoForm, Siemens NX), and PLC programming (e.g., Allen-Bradley, Siemens)
4+ years of experience in leading root-cause analysis, process optimization, and equipment upgrades using methodologies like Six Sigma, Lean Manufacturing, or Kaizen
4+ years of experience in with industrial automation, including robotics (e.g., Fanuc, KUKA), vision systems, and communication protocols (e.g., EtherCAT, Profinet)Excellent problem-solving skills with a track record of resolving equipment issues in 24/7 production settings
Requires domestic travel up to 5% and international travel up to 5% in order to support design reviews, equipment acceptance testing and global equipment installation efforts
Employer will accept any suitable combination of education, training, or experience

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