Process Engineer, Body in White, Megapack

What to Expect
The BIW Production Engineer drives process sustainment and continuous improvement on Tesla’s BIW structure line, building the foundation for commercial-scale energy storage products. The candidate will apply lean manufacturing principles to monitor yield, fallout, and critical process parameters, delivering measurable improvements in quality, safety, and efficiency. This role requires close collaboration with manufacturing engineering, new product introduction, quality engineering, equipment engineering, and production teams. Strong interpersonal and communication skills are essential. In this role you will lead root cause analysis of test failures and non-conformances, develop rework procedures, and ensure every issue is resolved at the source.

What You’ll Do

• Develop deep expertise in fixturing and welding manufacturing processes through data analysis and product understanding. Use this insight to optimize line layouts, material flow, waste reduction, and ergonomics using Lean Manufacturing principles
• Lead root cause analysis of complex system failures using a systems approach. Identify and mitigate failure modes to prevent recurrence across production
• Analyze and optimize production processes to ensure safety while maximizing Overall Equipment Effectiveness. Drive continuous improvement initiatives to achieve world-class quality and operational performance
• Lead continuous improvement projects to enhance critical KPIs including safety, quality, output, and cost. Establish and monitor SPC for key process parameters, then analyze data and implement Engineering Change Orders
• Own NCM (non-conforming material) activities, including documentation, troubleshooting, and failure analysis. Develop and validate rework procedures and create troubleshooting guides for offline failure resolution
• Diagnose issues in the part manufacturing process and drive corrective actions back to the source. Use structured problem-solving techniques such as DMAIC, 5W, Ishikawa, and 8D to identify root causes and eliminate systemic risks
• Support manufacturing and engineering activities including 5S, material handling improvements, production line configuration, and safety compliance
• Monitor and reduce process variation using Statistical Process Control and Measurement Systems Analysis. Audit manufacturing processes to ensure compliance with product specifications and standards. Contribute to the development and maintenance of FMEAs and Control Plans
• Create and maintain manufacturing instructions, routings, and process documentation. Train sustaining technicians and production operators. Manage daily activities of process sustaining teams to ensure line coverage and consistency
• Support 24 by 7 production operations, responding quickly to issues and ensuring rapid recovery with minimal disruption

What You’ll Bring

• Degree in Engineering, or equivalent experience in welding technologies
• Proven ability to read and interpret engineering prints and CAD files. Experience validating tooling, fixturing, and GD&T requirements
• Experience in Design for Manufacturability, Poke Yoke, and risk reduction through design. Ability to provide actionable recommendations to improve process robustness
• Background in automated systems including tooling, fixturing, sealing, and welding. Experience supporting troubleshooting and engineering activities during new product introduction
• Comfortable working with ambiguity and eager to dive deep into unfamiliar systems or challenges. Self-driven and curious with a strong learning mindset
• Demonstrated success in developing and improving tooling and welding processes. Track record of improving Overall Equipment Effectiveness and reducing yield loss
• Solid understanding of Bill of Materials, Manufacturing Execution Systems, Specification Management, and Change Point Management
• Strong problem-solving skills with proficiency in structured methodologies such as DMAIC, 5W, Ishikawa, and 8D. Ability to break down complex issues into actionable steps and apply Statistical Process Control effectively
• Excellent written and verbal communication skills. Ability to collaborate effectively across engineering, production, and maintenance teams
• Automotive ME, IE, or BIW experience is preferred