Sr. Reliability Engineer, Thermal & Mechanical, Energy Products

As a Mechanical Reliability Engineer focusing on Teslas energy products specifically, Megapack, you will play a key role in designing reliability into Teslas industrial energy storage systems, ensuring the products meet the highest standards of reliability. This role follows the reliability lifecycle of the product from concept to design validation, testing, analysis, manufacturing, and field operation to design-in confirm and grow exceptional reliability at every stage.

You will investigate failures through physics of failure analysis and physical testing to accurately predict the systems robustness and optimize product reliability while accelerating Teslas next-gen products time to market. This role is ideal for an Engineer who is passionate about reliability physics, enjoys problem-solving, and thrives in a fast-paced collaborative environment. Level will be determined after the interviews are completed.

Facilitating Design FMEA Sessions

Facilitate Design FMEA sessions to detect risks, drive reliable design choices, and inform validation testing. Set and communicate reliability requirements and targets for site, product, subsystem, and components.

Defining Reliability Test Plans

Define reliability test plans, design test conditions, set test duration, and sample size based on physics of failure modeling and accelerated life testing principles.

Analyzing Lab and Field Data

Analyze lab test data and field data to identify reliability trends, forecast reliability estimates utilizing statistical analysis (e.g., Weibull analysis, physics of failure models), and recommend design improvements.

Communicating Results and Recommendations

Communicate and drive test plans, results, learnings, and recommendations to various stakeholders within the organization.

Collaborating with Cross-Functional Teams

Closely collaborate with cross-functional teams, including test, reliability, data science, design, architecture, modeling, service, and quality, to identify potential reliability issues and drive corrective actions.

Researching Failure Mechanisms

Research failure mechanisms to build more robust validation plans and influence design choices.

Driving Reliability Assessments

Drive reliability assessments in product design reviews and clearly communicate risk at each phase of product development and for released products.

Influencing Supplier Selection

Influence supplier selection for higher reliability and provide clear guidance on reliability requirements and demonstration to suppliers.

Facilitating Failure Analysis

Facilitate failure analysis to understand root cause and drive resolution of failures occurring during product development phases.

Providing Reliability Design Guidelines

Provide reliability design guidelines and apply reliability lessons learned to enable continuous improvement.

Answering Complex Questions

Answer complex questions on fleet usage and behavior to enable proactive health monitoring, grow reliability, and minimize field failures.

Requirements

• Bachelors Degree in Mechanical Engineering, Materials Engineering, or a related field
• Three years of experience in a Reliability Engineering role or equivalent experience
• Understanding of accelerated testing methods, governing equations, and physics of failure for different failure mechanisms
• Understanding of applied statistics and reliability statistics (Weibull distribution, Maximum Likelihood Estimation, Bayesian methods, Monte Carlo analysis)
• Understanding of Accelerated Degradation modeling and reliability prediction methods
• Knowledge of material degradation mechanisms and their impact on mechanical performance
• Experience analyzing test results and interpreting reliability insights
• Knowledge of reliability growth techniques (Crow-AMSAA and Crow Extended)
• Knowledge of the ReliaSoft Synthesis Platform (Weibull BlockSim, ALTA, RGA, xFMEA)
• Working knowledge of failure analysis techniques (optical microscopy, SEM, Scanning Electron Microscopy, CSAM, Confocal Scanning Acoustic Microscopy, X-ray cross-sectioning, and EDX)
• Working knowledge of programming languages (preferably Python or Matlab)

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 with 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)
• 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 with a 90-day waiting period
• Employee Assistance Program
• Sick and Vacation time
• Flex time for salary positions
• Accrued hours for Hourly positions
• 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

The expected compensation for this position is $91,600 - $195,600 per year, with cash and stock awards and 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.