Sr. Staff Manufacturing Engineer, General Assembly & Test, Optimus

Tesla is seeking a highly motivated Sr. Staff Manufacturing Engineer to build and lead a team of engineers focused on high-volume production launches. This role will drive the development of scalable manufacturing systems while collaborating with cross-functional teams to optimize product designs for manufacturability, accelerate assembly processes, and implement automation solutions. In this fast-paced, demanding environment, you’ll play a pivotal role in scaling Tesla’s AI robotics initiatives while advancing our mission to achieve sustainable abundance through innovative manufacturing practices.

Responsibilities

Lead Manufacturing Engineering Team: Build, mentor, and scale high-performing teams to design and deploy high-volume production systems, ensuring alignment with Tesla’s speed and quality objectives Collaborate with Equipment Suppliers: Partner with internal and external suppliers to engineer, install, and validate production equipment, accelerating line ramp-up to meet volume targets Validate Requirements and Constraints: Use first principles analysis to rigorously assess product and process requirements, eliminating ambiguity and ensuring all elements are purpose-driven and essential Optimize Production Processes: Identify and remove non-value-added steps in workflows, prioritizing functional simplicity before pursuing automation or advanced optimization Improve Cycle Time: Analyze production bottlenecks and implement solutions to increase process speed, throughput, and overall line efficiency Deploy Automation Solutions: Strategically integrate automation as a final step after process simplification, ensuring systems are robust, high-speed, and scalable Ensure Seamless Operational Transitions: Coordinate with operations teams during ramp-up phases, delivering detailed documentation and training to sustain engineering teams for long-term success

Requirements

First Principles Thinking: A rigorous mindset focused on breaking down complex problems to their fundamental truths, enabling innovative solutions to manufacturing challenges Proficiency in CAD tools (Catia and AutoCAD preferred) for designing and optimizing production systems Deep knowledge of mechanical assembly techniques (pressing, fastening, harnessing, etc.) and electrical integration, including quality control matrices, testing protocols, and troubleshooting methodologies Familiarity with torque tools, automation equipment, control systems, and communication protocols (e.g., PLC, HMI, SCADA) Production Transition Experience: Demonstrated success in scaling products from prototype to high-volume production, ensuring seamless handover to sustaining teams Resilience & Adaptability: Ability to thrive in high-pressure environments while managing competing priorities and tight deadlines Communication & Organization: Exceptional verbal and written communication skills, paired with meticulous attention to detail and a highly organized approach to documentation and process handover Bachelor's Degree in Mechanical or Electrical engineering, or equivalent experience