Process Engineer, LFP Stack Module

Tesla is seeking a driven and innovative Process Engineer to help scale and refine our next-generation battery stack module manufacturing operations. In this role, you will work at the intersection of pioneering stack module technologies and high-volume production, helping to define the processes that power Tesla's mission to accelerate the world's transition to sustainable energy. As a Process Engineer, you will develop, implement, and optimize advanced manufacturing methodologies that enable efficient, high-quality, and scalable production of Tesla's cutting-edge stack module technologies. Improve product flow and manufacturing efficiency through data-driven process design, including tool and fixture development, ergonomic optimization, material presentation, 5S, Kaizen, Gemba practices, and Six Sigma principles. Collaborate closely with Design, Test, and Quality Engineering teams to enhance manufacturability, solve complex production challenges, and drive continuous process improvements. Partner with Quality to analyze production data, establish process control limits, and define key variables for both materials and manufacturing processes. Lead initiatives that reduce cost, improve yield, and enhance the robustness of Tesla's stack module manufacturing systems. This is a unique opportunity to contribute to the industrialization of breakthrough battery technologies, working hands-on in a fast-paced environment that rewards curiosity, creativity, and precision.

• Collaborate with cross-functional teams in the development of process flows, control plans, GR&R, work instructions, process capability, rework procedures, calibration and qualification of tools, quality validation, risk assessments (PFMEA), and 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
• 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
• Analyze and optimize production processes to ensure safety while maximizing Overall Equipment Effectiveness (OEE) in cost-effective means while driving world-class quality levels; champion continuous improvement projects (CIP) to maximize yield, capacity, and capability
• Diagnose issues found during the part manufacturing process and drive corrective action back to source, resulting in root cause identification and elimination; utilize structured problem-solving techniques such as DMAIC, Ishikawa, Five Why (5W), and Eight Disciplines (8D)
• 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
• Create and maintain Manufacturing Instructions, routings, and associated processes; manage activities for process sustaining technicians to support day-to-day coverage of production, including developing and documenting appropriate rework procedures
• Integrate and sustain MES (Manufacturing Execution Systems) for area of ownership to enhance traceability and manufacturing performance
• Degree in Engineering, or equivalent experience
• Knowledge of Statistical Process Control and its application, preferred
• 4+ years in a high-volume, highly automated manufacturing facility developing and improving processes, is a plus
• Experience developing and improving processes with a demonstrated track record of Overall Equipment Effectiveness improvement activities, preferred
• Strong problem-solving skills and 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, preferred
• Experience in the use of a broad variety of test, control, and data acquisition equipment and software is preferred
• Strong ability to work and communicate effectively with team and peers within a manufacturing and engineering organization, including excellent written and verbal communication skills, is a plus
• Experience on winding systems, industrial roll-to-roll 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