Sustaining Reliability Engineer, Low Voltage Systems

We are looking for a Sustaining Reliability Engineer, Low-voltage (LV) electronics with background in LV electronics modules and components. In this role, you will be at the forefront of our commitment to quality and reliability, executing a range of responsibilities that directly impact our products performance and customer satisfaction. As a successful candidate, you will be responsible for identifying risks and designing and implementing mitigation strategies associated with the manufacturing of our products, from mass production through the hands of our customers. Beyond traditional reliability engineering, this role also draws on data and light analytics to help detect and anticipate failures before they reach the field.

This role is highly engaging, and you will work with various internal and external cross-functional teams and management. You will oversee validation testing and convey the results to all involved teams. You will play a pivotal part in transitioning from New Product Introduction (NPI) to mass production while also enhancing our technology and volume scaling partnerships by cultivating and validating capable suppliers. You will develop and implement targeted validation plans and procedures for internal manufacturing teams as well as external suppliers to provide early detection of reliability issues during mass production. You will assess manufacturing changes and risks, develop test plans to validate them, and oversee root cause analysis for failures identified in tests. You must have a genuine passion for engineering products that will fundamentally change the world, and you must be self-motivated with the desire to push boundaries. If you have a strong technical first-principles understanding, excellent problem-solving skills, and a genuine fascination for engineering, this is an exciting opportunity to contribute to the cutting-edge technology of Tesla s products and shape the future. It comes natural to you to deliver results under high pressure with tight schedules. The level of this position will be determined at the time of the interview.

• Mitigate manufacturing risks and ensure product reliability during scaling, ramping, and high-volume production across global factories

• Oversee production validation, early-life reliability monitoring, supplier qualification, and smooth NPI-to-mass production transitions

• Apply expertise in reliability methods and low-voltage electronics to develop accelerated test plans for sustaining activities, including burn-in, ESS, ORT, and reliability growth demonstration

• Generate validation test plans for manufacturing, process, or supplier changes (internal/external), and drive root cause corrective actions

• Collaborate with quality, service, supplier, and design teams to conduct failure analysis and resolve testing/field failures; cascade reliability risks from design DFMEA into process PFMEA and control plans

• Analyze field usage, environmental conditions, and reliability metrics to optimize test methods and requirements for ongoing production

• Provide reliability guidelines, apply lessons learned, and use statistical methods to enable continuous improvements in manufacturing and early-life performance

• Work closely with Field Reliability Teams to identify and drive mitigation for field excursions related to manufacturing deviations, maintaining a closed loop with the New Product Introduction (NPI) reliability teams so field issues are consistently captured and actioned

• Pull together vehicle fault signals and environmental stress data (e.g., temperature, memory usage) and use light analysis to surface fleet risk and anticipate low-voltage failures

• Maintain stakeholder-facing dashboards that combine these insights with Jira issues and reliability test results (validation, ESS, ORT), and use AI/LLM tools to speed up fault diagnosis and root cause analysis

• Degree in Mechanical Engineering, Electrical Engineering, Materials Engineering, Acoustic, or equivalent experience

• 5+ years of experience with low-voltage electronic components/systems and laboratory testing (including relevant internships or academic lab work)

• Understanding of manufacturing processes for electronic components

• Experience with burn-in testing, Environmental Stress Screening (ESS), and Ongoing Reliability Testing (ORT)

• Understanding of highly accelerated testing methods and governing equations for acceleration models (e.g., Arrhenius, Coffin-Manson, inverse power law), and reliability growth modeling

• Experience developing reliability guidelines and innovative testing approaches for sustaining production

• Working knowledge of reliability statistics, including Weibull analysis, and tools like JMP or Minitab, ReliaSoft, MATLAB

• Working knowledge of failure analysis techniques, such as optical microscopy, SEM, CSAM, X-ray, cross-sectioning, and EDX, and root cause analysis methods such as fault tree analysis

• Proven ability to stay engaged, proactive, and positive in challenging situations

• Working knowledge of SQL and Python for data analysis, and comfort using dashboard/visualization tools to share results with stakeholders

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

Expected Compensation

$91,600 - $316,800/annual salary + cash and stock awards + benefits

Pay offered may vary depending on multiple individualized factors, including market location, job-related knowledge, skills, and experience. The total compensation package for this position may also include other elements dependent on the position offered. Details of participation in these benefit plans will be provided if an employee receives an offer of employment.