Staff Industrial Engineer, Megapack

Tesla is looking for a highly-motivated and accomplished Staff Industrial Engineer to join Energy Manufacturing team. Through a detailed understanding of the factory objectives and extensive collaboration with internal and external teams, you will help optimize our manufacturing and material flow process. This role presents a unique opportunity to contribute to the world-class manufacturing facility in Brookshire, TX, working in a demanding and fast-paced environment to improve critical subsystems of an exciting product.
We are seeking an Industrial Engineer or Continuous Improvement Engineer who has mastered Lean through a hands-on approach and who leverages its tools and methodologies to transform and scale operations. The key differentiator is direct, personal application: they have designed the cell, led kaizen events, performed line balancing, written the standard work, and owned the before-and-after results. Coaching and training others come only after they have already done the work themselves. The ideal candidate effectively facilitates problem-solving and continuous improvement activities, is pragmatic, influences without direct authority, demonstrates a strong bias for action, and delivers sustainable results in a fast-paced manufacturing environment.

- Design and improve assembly line layouts, support space, and amenity areas using a combination of quantitative analysis and lean principles

- Evaluate existing and future state factory layouts and workflows to support footprint expansion and efficient space utilization

- Deep dive into production assumptions (yield, line speed, equipment availability, cycle time) to identify risks, bottlenecks, and optimization opportunities, transforming raw data into strategic recommendations

- Develop buffer strategies, shift schedules, and labor models

- Perform line balancing, WIP management, and headcount optimization to align with takt time and throughput goals

- Support production planning by modeling throughput capabilities and identifying capacity constraints

- Lead continuous improvement initiatives across manufacturing operations and apply structured problem-solving methodologies

- Develop and implement standardized metrics, dashboards, and visualization tools to monitor and drive performance

- Mentor and train junior engineers and technicians

- 8+ years of hands-on experience in Industrial Engineering within a manufacturing or supply chain environment (energy, automotive, or warehousing preferred)

- Degree in Industrial Engineering, Manufacturing Engineering, or a related field, or equivalent experience

- Proven track record in driving complex engineering projects across cross-functional teams, excellent verbal and written communication skills, able to effectively convey complex ideas across technical and non-technical stakeholders

- Experience in capacity modeling, simulation (FlexSIM or similar), and operations research

- Deep familiarity with lean manufacturing, process optimization, work measurement, and line balancing techniques

- Experience with 2D CAD for layout design, 3D CAD for Process Engineering Support for fixture designs, understanding of automation, semi-automated lines, and robotics

- Proficient in AutoCAD, Revit, SQL, Excel VBA, Python, and data visualization platforms (e.g., Power BI, Tableau)

- Demonstrated ability to apply lean tools (VSM, 5S, Kaizen, Yamazumi charts) and Six Sigma principles (DMAIC, Control Plans)

- Experience with WMS or ERP platforms and understanding of master data, BOMs, and MRP logic

- Provide support to Engineering, Operations, Inventory Control, Production, Quality, Logistics, NPI, Training in all formats dependent on business need and maturity

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