Process Engineer, Dimensional, Megapack

What to Expect

The Process Engineer will be responsible for process sustaining and continuous improvement on the production line, building Tesla’s commercial scale energy storage product. This position will be responsible for GD&T of weld fixture and supplier parts, applying knowledge of weld distortion and fixture limitation to create subassemblies comparable to design intent. Daily work will be highly cooperative in nature with regularly interactions with manufacturing engineering, new product introduction, quality engineering, equipment engineering, and production operators – strong interpersonal skills are critical. The engineer will place a significant focus on troubleshoot and root cause of dimensional inaccuracy and subassembly variation, using a data driven approach. Role requires proficiency in rework process development.

The Process Engineer should be detail focused with an understanding of the big picture. They must be curious, self-motivated, receptive to feedback, and appreciate an environment where superior work is encouraged, noticed and rewarded.

What You’ll Do

• Develop expertise in manufacturing processes. Understand process capabilities through critical data analysis and in depth understanding of the product and tooling. Participate in the transition of a product from concept to pilot line production and into mass manufacturing
• Root Cause analysis of dimensional accuracy and subassembly variation due to incoming parts, MIG weld distortion and limitations in weld fixture
• Analyze and optimize production processes to ensure safety while maximizing Overall Equipment Effectiveness (OEE) in cost effective means while driving to achieve world-class quality levels. Champion continuous improvement projects (CIP) to maximize yield, capacity, and capability
• Lead continuous improvement activities to drive improvements to critical KPIs: safety, quality, output, and cost. Establish and monitor SPC for all critical process parameters, then analyze, develop, process, and implement Engineering Change Orders
• Lead NCM (non-conforming material) activities, including the documentation and troubleshooting of line fall out. Design, validate, and document rework procedures for non-conforming material and outgoing weld or dimensional inaccuracy
• Responsible for diagnosing issues found during the part manufacturing process and drive corrective action back to source, resulting in root cause identification and elimination. Responsible for shim logs at designated tooling
• Design or redesign tooling, weld schedule and weld process order to drive greater output dimensional accuracy relative to design intent
• 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
• Support 24/7 production operations

What You’ll Bring

• Degree in Mechanical, Electrical, Mechatronics, Robotics Engineering, or equivalent experience
• Experience commissioning and optimizing equipment.  Have a demonstrated track record of Overall Equipment Effectiveness (OEE) and dimensional accuracy improvement
• Extensive experience in GD&T and tooling design for consistent dimension after MIG weld
• 5+ years in an automated, high volume manufacturing facility
• Able to read and interpret part and product 2/3D CAD with ability to alter the field to replicate design intent
• Experience with automated MIG weld of steel is highly prized. Lincoln/FANUC is a plus