Staff Process Engineer, Optimus

Tesla is seeking a highly motivated Staff Process Engineer to develop advanced robotic manufacturing processes, supporting the world-class production of Tesla’s cutting-edge Optimus humanoid robots—an integral component of the next generation of Tesla products. The Staff Process Engineer will work with cross-functional teams (Design, Manufacturing, Equipment, Quality, and NPI Engineering) throughout the entire product lifecycle and process development. They will be involved from initial design, through prototype development, and finally into full production as well as implement, develop, and optimize sound production methodologies. This role will specialize in humanoid bot manufacturing, with a strong emphasis on enhancing SPARC (Safety, People, Accuracy, Rate, Cost) metrics and addressing the most complex challenges within the business unit. Tesla is a demanding and fast-paced environment where you will work on a critical subsystem in world-changing products and build the process foundations for the next generation of Tesla manufacturing.

Responsibilities

Play a lead role in the transition of the Optimus humanoid bot assembly from concept / pilot production / mass production by providing a roadmap toward high volume, production readiness Responsible for developing the framework and optimizing core factory metrics related to Overall Equipment Effectiveness (OEE) and process optimization that may include, but is not limited to equipment controls, tool/fixture selection, line layouts, ergonomic study, material presentation, and other relevant factors. Champion continuous improvement projects (CIP) to maximize yield, capacity, and capability Establish and standardize data pipelines from various sources to identify trends in build quality and efficiency. Develop standards for robust and clear data collection, visualization, and analysis tools. Enable data driven operational and financial decisions through predictive insights into tool and process performance, including integration of factory data systems and use of software such as MySQL, Python, R, JMP, Minitab, Tableau and Ignition Responsible for diagnosing issues found during the manufacturing processes which include but not limited to press, dispense, structural fastening, electro-mechanical testing test (such as dynamometer testing, hi-pot test, functional test & leak test) and drive corrective action back to source, resulting in root cause identification and elimination. Utilize structured problem-solving techniques such as DMAIC, Ishikawa, Five Why (5W) and Eight Disciplines (8D) Develop monitoring techniques for the cross-functional teams and reduce process variation using tools such as Statistical Process Control (SPC) and Measurement Systems Analysis (MSA). Monitor and audit manufacturing processes to ensure product specifications and standards are achieved. Drive the development and maintenance of FMEAs and Process Control Plans Implement robust frameworks to ensure compliance and effectiveness in production change control activities across the manufacturing program, while overseeing the execution of mission-critical Production Change Approvals (PCAs) Perform supporting activities for engineering and manufacturing including 5S and Lean manufacturing activities, material handling improvements, production line configuration, and safety procedures Mentor and train junior engineers, while providing support for operator training as required; direct process engineering teams in achieving manufacturing KPIs and support NCM through established rework and response protocols Support 24/7 production operations

Requirements

8+ years working on processes within high volume automation and/or electro-mechanical production systems Bachelor’s Degree in Engineering, Robotics, Mathematics, Physical Science or other applicable degree or equivalent experience Must have a demonstrated track record of ramping a high volume, automated and semi-automated battery manufacturing line Good understanding of Bill of Materials (BOMs), Manufacturing Execution System (MES), Specification Management, Change Point Management Data collection and analysis experience. Ability to develop data driven root cause analyses and solutions using tools such as MySQL, Python, R, JMP, Minitab, Tableau and Ignition Strong problem-solving skills and an aptitude for learning systems quickly. Able to utilize structured problem-solving techniques such as DMAIC, Ishikawa, Five Why (5W) or Eight Disciplines (8D). Able to resolve high level performance issues into addressable actions Ability to adapt to a flexible schedule in a fast-paced, dynamic manufacturing environment