Process Engineer, LFP Stack Module

What to Expect Tesla is seeking a driven and innovative Process Engineer to help scale and refine our next-generation battery stack module manufacturing operations. In this role, you will work at the intersection of pioneering stack module technologies and high-volume production, helping to define the processes that power Tesla’s mission to accelerate the world’s transition to sustainable energy. As a Process Engineer, you will develop, implement, and optimize advanced manufacturing methodologies that enable efficient, high-quality, and scalable production of Tesla’s cutting-edge stack module technologies. Improve product flow and manufacturing efficiency through data-driven process design, including tool and fixture development, ergonomic optimization, material presentation, 5S, Kaizen, Gemba practices, and Six Sigma principles. Collaborate closely with Design, Test, and Quality Engineering teams to enhance manufacturability, solve complex production challenges, and drive continuous process improvements. Partner with Quality to analyze production data, establish process control limits, and define key variables for both materials and manufacturing processes. Lead initiatives that reduce cost, improve yield, and enhance the robustness of Tesla’s stack module manufacturing systems. This is a unique opportunity to contribute to the industrialization of breakthrough battery technologies, working hands-on in a fast-paced environment that rewards curiosity, creativity, and precision. What You'll Do Collaborate with cross-functional teams in the development of process flows, control plans, GR&R, work instructions, process capability, rework procedures, calibration and qualification of tools, quality validation, risk assessments (PFMEA), and new product introduction Collaborate with Original Equipment Manufacturers in the commissioning and start of production of new automated manufacturing equipment; collaborate with EHS in the identification, prevention, and mitigation of safety hazards, proposing and implementing engineering solutions Develop expertise in manufacturing processes; understand process capabilities through critical data analysis and in-depth understanding of the product; develop and modify line layouts, including material flow, waste reduction, and ergonomics, utilizing Lean Manufacturing best practices Analyze and optimize production processes to ensure safety while maximizing Overall Equipment Effectiveness (OEE) in cost-effective means while driving world-class quality levels; champion continuous improvement projects (CIP) to maximize yield, capacity, and capability Diagnose issues found during the part manufacturing process 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 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 Monitor and reduce process variation using techniques such as Statistical Process Control (SPC) and Measurement Systems Analysis (MSA); monitor and audit manufacturing processes to ensure product specifications and standards are achieved; participate in the development and maintenance of FMEAs and control plans; analyze, develop, process, and implement Engineering Change Orders Create and maintain Manufacturing Instructions, routings, and associated processes; manage activities for process sustaining technicians to support day-to-day coverage of production, including developing and documenting appropriate rework procedures Integrate and sustain MES (Manufacturing Execution Systems) for area of ownership to enhance traceability and manufacturing performance What You'll Bring Degree in Engineering, or equivalent experience Knowledge of Statistical Process Control and its application, preferred 4+ years in a high-volume, highly automated manufacturing facility developing and improving processes, is a plus Experience developing and improving processes with a demonstrated track record of Overall Equipment Effectiveness improvement activities, preferred Strong problem-solving skills and 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, preferred Experience in the use of a broad variety of test, control, and data acquisition equipment and software is preferred Strong ability to work and communicate effectively with team and peers within a manufacturing and engineering organization, including excellent written and verbal communication skills, is a plus Experience on winding systems, industrial roll-to-roll web handling, or similar is a plus Experience on X-ray imaging, vision systems, laser process, laser welding, or similar is a plus Overall experience on power electronics, electrical measurements, testing, and metrology systems is a plus Compensation and Benefits 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 Tesla is an Equal Opportunity / Affirmative Action employer committed to diversity in the workplace. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, age, national origin, disability, protected veteran status, gender identity or any other factor protected by applicable federal, state or local laws. Tesla is also committed to working with and providing reasonable accommodations to individuals with disabilities. Please let your recruiter know if you need an accommodation at any point during the interview process.