Equipment Joining Engineer, Body In White, Megafactory

As a key member of the Production Engineering team, the BIW Equipment Joining Engineer will provide guidance, correction, and documentation to operations teams in all BIW shops regarding breakdowns, continuous improvements, and standardization. The candidate should be able to independently create and implement sustaining practices for the weld circuit and joint stack up with standardized procedures that serve as guidelines for preventive maintenance.

This position has an AWS shift pattern with day or night shifts available. Candidates with a strong aptitude for learning and solving complex problems in a fast-paced environment will thrive in this role.

• Respond to production downtime by diagnosing and resolving failures in joining equipment weld circuits and weld controllers to restore operations quickly and sustainably.
• Lead end-to-end resolution of joining process faults and joint non-conformances through root cause analysis and implementation of corrective and preventive actions.
• Maintain manual and robotic joining processes by applying best practices to improve equipment longevity, process quality, and preventive maintenance effectiveness.

Key fault examples:

• Resistance checks

• Blowhole recovery

• C-factor deviations (high/low)

• Current tip dress faults

• Excessive adhesive squeeze-out

• Mislocated laser brazing seams

• Wire feed issues

• Remote welding cooling system failures

• Cover lens integrity

• Optimize KUKA-based welding and joining systems using deep understanding of robot position, speed, motion profiles, and process dynamics to diagnose and correct issues such as expulsion, arcing, stick-out, tip wear, cooling inefficiencies, contamination, and inconsistent nugget formation size and location.

• Support manufacturing engineering CapEx projects from factory acceptance testing (FAT) through installation, commissioning, validation, and transfer of ownership to production, including joint development and validation execution.

• Develop and deliver technical training for maintenance, production, and engineering teams to build internal capability, standardize practices, and ensure long-term process reliability.

• Troubleshoot chronic equipment failures and complex breakdowns with hands-on support to maintenance and production teams, reducing repeat failures and downtime.

• Establish and execute destructive and non-destructive validation criteria for spot and MIG welds using data from quality reports to identify failure modes and drive improvements.

• Apply hands-on expertise in electrical, mechanical, and pneumatic systems to diagnose and resolve issues across joining equipment platforms.

• Collaborate cross-functionally with engineering, production, and maintenance teams to ensure process consistency, documentation accuracy, and continuous improvement in high-volume manufacturing environments.

Requirements:

• Degree in Engineering or equivalent experience in joining technologies and manufacturing systems.
• 3 years of hands-on experience with BIW automotive joining processes (self-piercing riveting, remote welding, spot welding, material dispensing, MIG welding, and laser brazing) with demonstrated proficiency in both manual and robotic systems.
• Experience with KUKA robotics systems preferred.
• Familiarity with weld controllers and robotic interfaces for spot welding.
• Prior experience with Bosch Weld Controllers preferred.
• Proficient in downtime tracking, daily pass-down reporting, and root cause analysis documentation.
• Full hands-on understanding of electrical, mechanical, and pneumatic systems within joining equipment.
• Experience with MIG welding circuits and joint development.
• Preference for Fronius TPSi Twin system experience and integration with KUKA robotics.
• Experience setting up and executing destructive and non-destructive validation criteria for spot and MIG welds.
• Proven experience with KUKA and Fanuc robotics for daily joining operations, including robot path and position teaching.
• Experience with motion optimization for weld quality is a plus.
• Strong interpersonal skills with a track record of resolving conflict constructively in large cross-functional teams.
• Effective verbal and written communication skills essential for technical collaboration, documentation, and training delivery.

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.
• 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).
• 401k 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.