Sr. External Warehouse Process Engineer, Production Control

As the Sr. External Warehouse Process Engineer, you are responsible for the design, implementation, and continuous improvement of external warehouse material flow, storage, and logistics processes with respect to safety, efficiency, cost, and quality. Through true cross-departmental collaboration, you will design and optimize warehouse layouts, capacity plans, densification strategies, and automated storage and retrieval systems - including ASRS and automated reach trucks - to support rapid scalability across our growing network.

This role also carries significant impact on first mile logistics optimization. Through end-to-end analysis of our warehouse portfolio, you will determine the most optimal PO destination for parts to reduce cost and improve velocity. Our current external warehouse footprint of 2.5M sq. ft. is expected to grow to over 5M sq. ft. in the next three years. Experience launching new warehouses from design through ramp is strongly desired.

Your work begins with strategic design but extends far beyond it. Through a continuous feedback loop with operations and engineering teams, you will relentlessly evaluate and improve processes by eliminating waste and non-value-added activities. This persistence for excellence is a core value of our team and critical to building a World Class material handling and logistics system.

• Collaborate with cross-functional teams (Supply Chain, Logistics, Planning, Packaging Engineering, Automation Engineering, and Software) to design and continuously improve all aspects of external warehouse material flow, storage, and operational processes
• Analyze data from multiple operating systems to develop and maintain PFEP (Plan For Every Part) at the warehouse network level
• Lead warehouse capacity planning and densification efforts, including granular layout design, racking optimization, headcount calculations and space utilization strategies to support rapid footprint growth from 2.5M to over 5M sq. ft
• Design input parameters, RFQ and implement automated material flow storage solutions, including ASRS (Automated Storage and Retrieval Systems), automated reach trucks, and other advanced automation technologies
• Perform end-to-end supply chain and first mile logistics analysis to optimize PO destinations across the warehouse portfolio, balancing cost, velocity, and operational efficiency
• Execute detailed warehouse layouts that maximize cubic utilization, material flow efficiency, safety, and visual management (including 5T signage)
• Develop standard work documentation for all warehouse processes including receiving, put-away, storage, retrieval, inventory management, and expendable/recyclable material handling
• Learn and configure our internally developed inventory management system (MFS - Material Flow System) to ensure systematic processes accurately reflect optimized physical operations
• Analyze current-state performance and lead process improvement initiatives focused on efficiency, safety, cost reduction, densification, and productivity
• Support new warehouse launch activities from initial design and equipment specification through successful operational ramp
• Bachelor's Degree in Engineering or equivalent experience
• 5+ years of experience in warehouse process engineering, material flow design, logistics engineering, or supply chain operations (Sr. level experience expected)
• Strong experience launching new warehouses from concept through operational go-live is strongly preferred
• Demonstrated expertise in warehouse capacity planning, densification strategies, and automated storage systems (ASRS, automated reach trucks, and related technologies)
• Superior knowledge of lean manufacturing and logistics principles, material flow optimization, and continuous improvement methodologies
• Proven ability to mine, cleanse, and analyze large datasets using Excel, SQL, or similar analytical tools
• Proficient in AutoCAD (Revit experience is a plus) for executing detailed warehouse layouts and designs
• Strong cross-functional collaboration and problem-solving skills with the ability to influence across multiple teams and levels
• Previous World Class Manufacturing or Lean Manufacturing experience

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