Staff Process Engineer

Tesla Energy in Sparks, NV is seeking a highly motivated and results-driven Staff Process Engineer to lead improvement initiatives across Energy Factory Nevada (EFNV) and Remanufacturing facilities. In this role, you will be a proven leader with deep expertise in lean manufacturing, kaizen facilitation, and cross-functional collaboration to drive operational excellence, cost reduction, and quality improvements across multiple production environments.

As the Staff Process Engineer, you will design and facilitate rapid improvement workshops, lead cross-functional teams through root cause analysis and countermeasure implementation, and establish standardized continuous improvement processes across diverse production lines including battery cell manufacturing, energy storage systems, and remanufacturing operations. You will deliver measurable results through structured problem-solving, waste elimination, and sustainable process optimization in high-volume manufacturing settings, contributing to Tesla s mission to accelerate the world s transition to sustainable energy.

• Lead and facilitate events across EFNV and Remanufacturing facilities, designing event scopes, assembling cross-functional teams, and driving rapid improvements in cycle time, quality, cost, and safety
• Coach and develop employees at all levels in methodology, lean tools, and problem-solving techniques, fostering a culture of continuous improvement
• Establish event calendar, prioritization framework, and tracking systems to align improvement activities with business objectives
• Conduct value stream mapping and lead workshops focused on 8 waste reduction, implementing lean principles including 5S, visual management, standard work, and poka-yoke
• Drive cycle time reduction initiatives for critical processes (e.g., EMX validation, cell mapper performance, backend MOS processes)
• Lead technical root cause analysis for complex quality and process issues using advanced problem-solving methodologies (8D, A3, 5-Why, Fishbone, DOE) and support CAPA development for critical issues
• Lead cost-saving initiatives and build optimized processes for COPQ tracking, MRB disposition, and escalation procedures to deliver measurable reductions in waste and spend
• Lead and manage engineering projects for test equipment development, validation process improvements, and production line optimization
• Define processes, create standards, and develop comprehensive SOPs for continuous improvement activities, validation protocols, and manufacturing processes
• Build cross-functional alignment across Quality, Production, Process Engineering, Material Planning, Supplier Quality, and Industrialization teams through Q-Team steering and collaboration
• Proven track record leading events and delivering measurable financial results in high-volume manufacturing environments; battery, electronics, or remanufacturing experience is a plus
• Expert-level knowledge of lean manufacturing principles, tools, and techniques (VSM, 5S, TPM, SMED, Kanban, JIT); Lean Six Sigma certification (Green Belt or Black Belt) is preferred
• Strong background in core quality tools (MSA, pFMEA, SPC, control plans, statistical analysis) and experience with MRB processes, containment strategies, and CAPA management
• Proficiency in problem-solving methodologies including 8D, A3, DMAIC, root cause analysis, and DOE
• Data-driven mindset with proficiency in data analysis, statistical tools, process mapping, visualization techniques, and experience developing KPIs, dashboards, and performance tracking systems
• Excellent facilitation and leadership skills with proven ability to lead diverse, cross-functional teams, drive change, influence without authority, and foster a culture of continuous improvement
• Strong communication and presentation skills in English, capable of conveying complex ideas to audiences ranging from frontline operators to executive leadership
• Demonstrated ability to operate effectively in fast-paced, startup-style environments while managing multiple priorities with a hands-on approach and willingness to spend time on the production floor
• Project management certification (PMP, CAPM) or equivalent experience is preferred