Process Engineer, Optimus Battery

Tesla is seeking a Process Engineer to ensure continuous production quality and enable world-class manufacturing of Optimus battery packs. The battery pack provides energy storage for Optimus. This role develops and sustains process standards for a critical subsystem in a demanding, fast-paced environment.

Your primary responsibilities are to eliminate waste in the manufacturing process and drive long-term line improvements to yield, cycle time, and process capability. You will also work with a cross-functional team to develop, introduce, and sustain new model, product, and material introductions. The ideal candidate is data-driven, hands-on, and comfortable leading structured problem-solving with Production in a high-volume automated and semi-automated factory.

This role supports production operations, including flexible hours during launch, ramp, and critical quality or yield events as business needs require.

• Analyze and optimize production processes to ensure safety while maximizing Overall Equipment Effectiveness (OEE), throughput, and world-class quality in a cost-effective manner

• Champion continuous improvement projects (CIP) to maximize yield, cycle time, availability, capacity, and process capability; review critical process metrics daily for statistical shifts from nominal, develop action plans, and report metrics to leadership

• Analyze data from multiple sources to identify trends in build quality and efficiency; develop data collection, visualization, and analysis tools, and enable predictive operational and financial decisions using MySQL, Python, Minitab, Tableau, and Ignition

• Diagnose manufacturing issues and identify root cause using structured problem-solving techniques such as DMAIC, Ishikawa, 5-Why, and 8D; implement permanent corrective actions

• Drive continual improvement with production staff through process audits, kaizen, 5S, Lean manufacturing, material handling improvements, production line configuration, and safety procedures

• Create and maintain Manufacturing Instructions, routings, control plans, validation and ramp reports, and training materials; develop and train sustaining technicians and assist in associate training as needed

• Partner with Equipment, Quality, Controls, NPI, and Design on new model, product, and material introductions; ensure processes are feasible, capable, and ready for high-volume production

• Apply Lean Six Sigma methods - waste reduction, poka-yoke, SPC, Gage R&R, and DOE - to reduce variation and scrap

• Support vision inspection systems (e.g., Keyence 2D image inspection and profilometry) as part of process control and quality feedback where applicable

• Support flexible hours during launch, ramp, and critical quality or yield events as business needs require

• Bachelor's Degree in Mechanical, Manufacturing, Industrial, Chemical, or another Engineering discipline, or equivalent experience

• Experience developing and improving manufacturing processes, with a demonstrated track record of Overall Equipment Effectiveness (OEE), yield, or process-capability improvement

• Demonstrated experience ramping a high-volume automated or semi-automated manufacturing line

• Ability to derive data-supported root causes and propose strong countermeasures; must be able to pull data using efficient SQL queries, with Tableau and/or Minitab preferred and Ignition, MES, and/or Python highly desired

• Experience developing and applying Lean Six Sigma methodologies such as waste reduction, poka-yoke, SPC, Gage R&R, and DOE

• Experience with vision inspection systems preferred (e.g., Keyence 2D image inspection and profilometry)

• Exceptional problem-solving skills and aptitude for learning systems quickly; proficiency with DMAIC, Ishikawa, 5-Why, and 8D

• Capacity to manage simultaneous activities and competing priorities in a fast-paced production environment

• Strong written and verbal communication skills; able to work effectively with Production, Quality, Equipment, Controls, NPI, and Design under changing priorities

• Ability to work hands-on on the factory floor and support production operations during launch, ramp, and critical events as business needs require

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
• Earned Wage Access: Real-time pay access paid daily, subject to eligibility and schedule (applicable for below Sr. Managers levels)