Manufacturing Quality Engineer, High Speed Stamping & Gears

In this role, you will own quality for high-speed progressive stampings and precision gears, in-house and at suppliers, on the Stamping Manufacturing Engineering team. You will define how laminated segment stators, related stampings and gears are measured, controlled and improved from first article to stable high-rate production. You will work with Design, Manufacturing and Supply Chain so quality requirements stay manufacturable and tied to actuator performance at Gigafactory Texas.

• Lead quality planning for progressive die stampings, including motor laminations, through PFMEA, control plans and PPAP or first article inspection
• Support die tryout, buyoff and ramp by reviewing strip layout and station sequence for burrs, springback, coil set, camber, edge quality and dimensional drift
• Define in-die sensing, process monitoring and inspection plans that keep pace with high strokes-per-minute rates
• Set coil incoming controls for properties, thickness, surface, lubricant, cleanliness and traceability, and tie die wear tracking to burr and clearance data
• Own quality requirements for gear processes such as hobbing, shaping, grinding, honing, broaching, powder metal and fine blanking
• Define gear inspection for profile, lead, pitch, runout and tooth thickness to AGMA, ISO and DIN, including noise, transmission error and backlash tests
• Specify and audit heat treatment, case depth, hardness, microstructure, distortion control and finishing, and correlate gear quality to actuator efficiency, noise, torque ripple and life
• Validate CMM, vision, optical, laser and gear measurement systems, including MSA and gage R&R
• Use SPC, capability studies and root cause corrective action to return GD&T and manufacturability lessons to Design and Manufacturing Engineering
• Degree in Mechanical Engineering or equivalent experience
• 3 years of experience in process optimization, root cause analysis, dimensional control and tooling adjustments
• GD&T, measurement equipment and CAD in CATIA, SolidWorks or AutoCAD
• Identify critical process parameters and apply statistics to process measurement and control
• Interpret measurement data, find trends and improve process or part capability through root cause analysis
• Preferred: high-speed stamping of thin-gauge, high-strength or electrical steel, die design principles and in-die sensors
• Preferred: gear metrology and noise testing; heat treatment and metallurgy; fine blanking or powder metallurgy; data analysis in Python, SQL, JMP or Minitab; ASQ CQE or Six Sigma certification
• Essential physical demands: work on the factory floor and at supplier sites, with domestic and international travel up to 25%, including trips of multiple weeks

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
• Earned Wage Access: Real-time pay access paid daily, subject to eligibility and schedule (applicable for below Sr. Managers levels)