Sr. Manufacturing Process Engineer, Robotics

The Sr. Manufacturing Process Engineer, Robotics, leads process design and industrialization efforts that deliver exceptional product quality and volumes for next-generation electric motors manufacturing. You will collaborate closely with cross-functional teams—including design engineering, die engineering, tooling suppliers, quality, automation, and operations—to improve throughput, reduce scrap and downtime, and ensure processes meet Tesla’s rigorous standards for performance, safety, and sustainability. This position blends advanced stamping expertise, materials science for electrical steels, tooling/process optimization, automation integration, and data-driven continuous improvement in a fast-paced, high-volume manufacturing environment.

Responsibilities

Develop, qualify, and optimize high-speed stamping processes (progressive, compound, or hybrid dies) for electric motor laminations from electrical steel coil, ensuring precise geometry, flatness, edge quality, and coating integrity to maximize motor efficiency and minimize core losses Specify, design/review, validate, and industrialize dies, tooling, press parameters, lubrication, strip feeding, and material handling systems tailored to electrical steels (silicon steels and advanced grades) Integrate and optimize automation elements—including robotics, PLCs, sensors, vision systems, servo/VFD controls, and end-of-line stacking/bonding equipment—to achieve high throughput, consistent quality inspection, and automated lamination stacking or interlocking Troubleshoot process, tooling, press, and automation issues on the production floor; lead root-cause analysis (RCA) and implement permanent corrective actions to minimize downtime and scrap Partner with product design, die engineering, tooling suppliers, quality, and maintenance teams on Design for Manufacturability (DFM), Design for Assembly (DFA), equipment validation (IQ/OQ/PQ), process capability (Cpk), and industrialization of new motor designs and production lines Drive continuous improvement initiatives using Lean Manufacturing, Six Sigma, and advanced methods—such as predictive maintenance, energy-efficient press operation, scrap reduction/recycling of electrical steel, and waste minimization—aligned with Tesla’s sustainability goals Support new product introduction (NPI) and production ramp-up by transferring processes into manufacturing, training operators/technicians, and ensuring robust, scalable workflows Ensure full compliance with safety standards (including safety PLCs and fail-safe systems), quality systems, regulatory requirements, and environmental goals throughout process and equipment lifecycle

Requirements

Degree in Mechanical Engineering, Manufacturing Engineering, or equivalent experience 5+ years of experience in manufacturing process engineering within high-volume production environments, preferably automotive, electric motors, precision metal stamping, or electrical steel/component manufacturing. Senior-level ownership of process development and industrialization is expected Proven expertise in high-speed stamping and metal forming processes for motor laminations or similar precision components, including progressive/compound die design and operation, press setup/controls (mechanical, hydraulic, or servo), coil feeding, and material science of electrical steels (e.g., silicon content, coatings, magnetic properties, grain orientation, and processing effects) Strong proficiency with process and tooling tools/software: CAD/CAM (SolidWorks, AutoCAD, or equivalent), die design/review, stamping process simulation, PLCs (Allen-Bradley, Siemens, etc.), robotics (Fanuc, KUKA, or similar), vision systems for quality inspection, and industrial communication protocols (EtherCAT, Profinet, etc.) Demonstrated ability to perform data analysis, statistical process control, root-cause analysis, and continuous improvement using Lean Manufacturing, Six Sigma (Green/Black Belt preferred), DOE, and tools such as Minitab or equivalent Knowledge of secondary lamination processes (stacking, interlocking, bonding, welding) and quality metrology (dimensional, optical, coating, and ideally magnetic property evaluation) is highly desirable Excellent problem-solving skills with a hands-on approach to debugging complex process and equipment issues in a production setting Ability to work in a fast-paced, dynamic environment with occasional overtime or shift work to support 24/7 manufacturing Travel as required for equipment/die supplier visits, trials or buyoffs (>5%)