Process Engineer, Optimus General Assembly

Tesla is seeking a Process Engineer to support the design, development and launch of a highly automated Optimus assembly line from concept through production ramp to rate, yield, and OEE targets.

You will partner with internal cross-functional teams and external vendors to run process design reviews and line layout reviews, develop processes and line balance, participate in Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT), and launch and ramp the manufacturing line to safety, rate, quality, and cost targets.

In this role you will collaborate to specify and buy off manufacturing process, validate performance against Tesla standards, resolve issues in real time during acceptance testing and factory floor. The ideal candidate is hands-on, data-driven, and comfortable working with internal stakeholders through a fast-paced NPI environment.

Travel expected 25% - ability to travel domestically and internationally to other Tesla factory locations and suppliers as required.

• Lead cross-functional process and manufacturing readiness reviews with Design, Quality, Tooling, Equipment, Automation, and Production to ensure processes are feasible, capable, and ready for high-volume production
• Develop, document, and implement manufacturing processes - process flows, MIs/routings/SOPs, cycle time studies, standard work - and maintain change control (PCAs/ECOs), specs, and BOM/MES alignment through launch and sustain
• Own line and workstation layout development and reviews, including product flow, material presentation, ergonomics, waste reduction, and Lean line configuration
• Develop and maintain process balance, takt/cycle time plans, bottleneck analysis, and capacity models to meet throughput and OEE targets
• Partner with Design on early DFM/DFA feedback; support tooling/fixture selection and poke-yoke; collaborate with Equipment and Controls on sequence of operations, process windows, and equipment performance
• Define critical process parameters; develop and maintain PFMEAs and control plans; implement SPC and process capability (Cpk/Ppk) to reduce variation and sustain quality performance
• Participate in FAT at supplier sites and SAT/site commissioning; define acceptance criteria, close process punch items, and support installation, commissioning, and production launch as the primary process technical resource
• Own process performance through ramp with Production - optimize cycle time, line balance, and process parameters in real time to hit rate, yield, first-pass yield, and quality targets
• Investigate quality escapes, yield loss, scrap/rework, and test/fallout failures; drive root-cause corrective actions (5-Why, Ishikawa, 8D, DMAIC, DOE/A3) and continuous improvement to Safety, Rate, Quality, Cost, and OEE
• Create handover documentation (process specs, MIs, validation/ramp reports, rework/NCM procedures) and train technicians and production personnel
• Bachelor's degree in Mechanical, Manufacturing, Industrial, Electrical, Mechatronics, or related engineering field, or equivalent experience
• 3+ years of process, manufacturing, or industrial engineering experience in high-volume manufacturing (automotive, electronics, energy, robotics, or similar preferred), including hands-on factory-floor work and flexible support during launch and ramp
• Experience developing and launching manufacturing processes from pilot/prototype through mass production, including process documentation, cycle time studies, production readiness, and change point management
• Experience with line/workstation layout, material flow, process/line balance, takt time, and capacity analysis for automated or semi-automated assembly lines
• Exposure to FAT, installation, SAT/commissioning, and production ramp of manufacturing equipment or lines; preferred experience writing process acceptance criteria and supporting vendor buy-off
• Working knowledge of PFMEA, control plans, SPC, process capability (Cpk/Ppk), MSA/GR&R, and Lean/Six Sigma methods (5S, Kaizen, VSM)
• Demonstrated track record investigating and improving quality and yield - including scrap/rework, fallout, first-pass yield, and process capability - using structured problem-solving and production data
• Familiarity with BOMs, MES, specification management, and manufacturing data tools (SQL, Python, JMP, Minitab, Tableau) to turn quality and yield data into actionable process improvements
• CAD proficiency for layouts and tooling review (AutoCAD, CATIA, SolidWorks, or similar); familiarity with automation, robotics, fastening, dispense, joining, vision, or end-of-line test processes preferred
• Excellent cross-functional communication skills; able to lead reviews and work effectively with Production, Quality, Equipment, Design, and vendors

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)