Sr. Manufacturing Engineer, Conveyance & Automation

Tesla's Manufacturing Engineering team is at the forefront of developing first-of-a-kind processes which allow us to produce amazing vehicles at best-in-class quality and rate in a safe and ergonomic environment. The Coatings team is seeking a Sr. Manufacturing Engineer - Conveyance & Automation to lead the design and development of material handling, conveyance, and automation systems used in the manufacturing of our products. This includes process development, specification, validation, establishing and optimization of critical process parameters, design for manufacturing, equipment specification and design, as well as installation and commissioning. The candidate will work closely with internal cross-functional teams, external vendors & technology partners on process development from concept to production. This role requires a thorough understanding of Manufacturing Engineering fundamentals and substantial skills with 2D or 3D CAD software. It is critical for a successful applicant to solve problems using first principles analysis and exercise aggressive design optimization. This position requires 25% travel.

• Lead cross-functional collaboration across process, equipment, mechanical, electrical, controls, project management, and manufacturing stakeholders for coatings conveyance and automation systems
• Document product and process requirements for conveyance, material handling, and automation equipment specification supporting pretreatment, e-coat, spray/application booths, and industrial ovens
• Lead design and development of conveyance and automation technologies from concept to serial production, including overhead power-and-free / monorail / EMS systems, skid and pallet conveyors, roller/belt/chain/slat conveyors, dip/immersion carriers and flight bars, lift/transfer/turn tables, drop sections, AGVs/AMRs, robotic load/unload cells, AS/RS, and in-line buffering/accumulation suited to wet process and high-temperature environments
• Perform detailed line design based on process requirements, throughput, takt/cycle time, buffer sizing, and OEE; define and optimize material flow parameters (speeds, accumulation, routing, recovery, dwell/index timing) for target throughput, uptime, and product/coating integrity through pretreat, e-coat, booths, and ovens
• Select, qualify, and manage conveyance equipment, EOAT, fixturing/pallets/carriers, hangers and racks, sensors, safety systems, and supporting utilities; account for chemical exposure, washdown, grounding/earthing for e-coat, and thermal duty in oven zones
• Analyze process cost per unit and drive system development that yields the greatest benefit; lead DFM/DFA and sustainability to lowest overall cost (BOM + manufacturing), including design for manufacturability, maintainability, and accessibility in a coatings shop environment
• Lead process and system qualification, including acceptance criteria and verification using statistical tools (GR&R, SPC, Cp/Cpk) and system metrics (OEE, MTBF, MTTR)
• Design and develop conveyance and automation systems that comply with safety regulations and industry standards; review compliance with machine safety, guarding, interlocks, hazard area classifications, fire codes, and applicable standards to maintain a safe working environment
• Develop and maintain documentation including equipment specifications, control plans, sequence of operations, and standard work instructions
• Manage large-scale projects for new programs: timing plans and cost breakdowns for executive approval, risk identification and corrective action, status reporting to the executive team, and oversight of installation and commissioning of new manufacturing lines; drive continuous improvement of existing conveyance and automation systems to improve quality, reduce cycle time, increase uptime, and lower cost per unit
• Degree in Manufacturing, Mechanical, Industrial, Mechatronics, or Engineering, or equivalent experience, with 5+ years of related experience in high-volume automated conveyance and material handling within finishing/coating or similar continuous/flow manufacturing, or equivalent experience
• Deep knowledge of industrial conveyance and material handling: overhead power-and-free / monorail / EMS, skid and pallet systems, roller, belt, chain, and slat conveyors; AGVs/AMRs; robotic transfer; AS/RS; and accumulation, sorting, and buffering methods - preferably in pretreatment, electro-deposition, paint/powder, or industrial oven lines
• Experience developing, installing, and commissioning high-volume conveyance and automation systems (production conveyors, transfer lines, dip/immersion carriers, robotic cells, AGV/AMR fleets, pallet/skid systems, lift/transfer stations, in-process tracking)
• Experience with industrial automation controls including PLC programming (Allen-Bradley, Siemens, or equivalent), HMI development, industrial networks, and safety PLCs
• Strong understanding of machine safety standards (ISO 13849, IEC 62061, ANSI B11, RIA R15.06), guarding, interlocks, and risk assessment; familiarity with hazard area classification, fire codes, and industrial oven safety standards (NFPA 86) is preferred
• Experience developing, executing, and interpreting DOE and discrete-event simulation (FlexSim, Tecnomatix Plant Simulation, or equivalent) for material flow and system optimization
• Experience using Industrial Engineering methods in high-volume manufacturing; proficient in CAD (CATIA, SolidWorks, Inventor, and/or AutoCAD) and reading and interpreting mechanical drawings and electrical schematics
• Proficient in PFMEA development and deployment; new product introduction and manufacturing operations experience desired
• Mastery of MS Office suite, Confluence, Jira, etc.
• 25% travel required

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

Expected Compensation

$109,600 - $234,000/annual salary + cash and stock awards + benefits

Pay offered may vary depending on multiple individualized factors, including market location, job-related knowledge, skills, and experience. The total compensation package for this position may also include other elements dependent on the position offered. Details of participation in these benefit plans will be provided if an employee receives an offer of employment.