Manufacturing Process Engineer - Optimus Factory Gears

About the Role

Tesla is inviting applications for a Manufacturing Process Engineer to contribute to the development and launch phases of the Optimus Gears manufacturing program. The position entails creating, enhancing, and maintaining specialized manufacturing procedures focused on precision gear production. You will lead the transition of automated lines from prototype stages through Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), and full-scale mass production (Start of Production - SOP).

Specialized Tracks

Applicants are expected to have expertise in at least one of the following specialized engineering streams; possessing knowledge in all is not mandatory:

• Heat Treatment processes such as induction or laser hardening
• Precision Machining techniques
• Gearbox Assembly operations
• End-of-Line Testing procedures
• Advanced Metrology, including Coordinate Measuring Machine (CMM) programming, inline automated gauging, Geometric Dimensioning and Tolerancing (GD&T), and Gage Repeatability and Reproducibility (Gage R&R)

Key Responsibilities

• Take full ownership of assigned technical track to enhance and scale operational performance.
• Design, implement, and evaluate formal Design of Experiments (DOE) to determine critical process parameters, reduce variation, and define optimized baselines for complex mechatronic components.
• Develop process documentation including process flows, Process Failure Mode and Effects Analysis (PFMEA), Control Plans, and standardized work instructions.
• Assist in developing equipment specifications and respond to supplier Requests for Quotes (RFQs).
• Participate in equipment design reviews and oversee process validation activities.
• Support equipment installation, FAT, SAT, and commissioning processes.
• Establish process capability metrics and criteria for manufacturing acceptance.
• Lead initiatives to improve safety standards, product quality, throughput, cycle times, and Overall Equipment Effectiveness (OEE).
• Contribute to pilot builds and production ramp-up efforts.
• Apply root cause analysis and corrective problem-solving techniques, integrating first-principles engineering and data-driven methods to resolve equipment failures, process constraints, and quality issues.

Qualifications and Skills

• Bachelor’s degree or equivalent practical experience in Mechanical, Industrial, Manufacturing Engineering, Metrology, or related disciplines.
• Demonstrated hands-on experience launching and fine-tuning equipment within at least one assigned technical track.
• Proficiency in statistical methods, including Design of Experiments (DOE), Statistical Process Control (SPC), and data-driven process optimization.
• Familiarity with PFMEA, Control Plans, SPC, and Lean Manufacturing principles.
• Strong analytical aptitude and problem-solving capabilities.
• Knowledge of robotics, automation systems, and machine vision technologies.

Travel Requirements

This position requires approximately 25% travel time, including domestic and international visits to supplier locations as needed.

Compensation and Benefits

• Eligibility for medical plans with options that include zero payroll deductions.
• Family building support, including fertility, adoption, and surrogacy assistance.
• Dental care including orthodontics and vision plans with options available at no paycheck contribution.
• Employer contributions to Health Savings Accounts (HSA) with high-deductible medical plans.
• Flexible Spending Accounts (FSA) for healthcare and dependent care.
• 401(k) with company matching, Employee Stock Purchase Plans, and other financial incentives.
• Paid Basic Life and Accidental Death and Dismemberment insurance.
• Short-term and long-term disability coverage (90-day waiting period applies).
• Employee Assistance Program access.
• Paid sick leave, vacation time (flexible for salaried, accrued for hourly employees), and holidays.
• Backup childcare services and parenting support resources.
• Optional voluntary benefits like critical illness, hospital indemnity, accident insurance, legal services, theft protection, and pet insurance.
• Programs for weight loss and tobacco cessation.
• Tesla Babies program benefits.
• Commuter benefits.
• Employee discounts and perks programs.