Process Engineer, Optimus Actuators

Tesla is seeking a Process Engineer to support Optimus Actuators manufacturing — production of electromechanical actuators that convert electrical energy into controlled physical motion. You will own process development, sustaining, and continuous improvement across multiple highly automated production lines from launch through rate, yield, and OEE targets.

You will partner with Manufacturing Engineering, NPI, Quality, Equipment Engineering, Controls, and Production to validate processes, troubleshoot end-of-line (EOL) failures and fallout, lead NCM activities, and apply lean and statistical methods to drive yield and capability. Where associates are required to support automated operations, you will define staffing needs and recruitment timelines. The ideal candidate is hands-on, data-driven, and comfortable leading structured problem-solving in a fast-paced NPI and high-volume manufacturing environment.

Travel expected as business needs require — ability to travel domestically and internationally to other Tesla factory locations and suppliers as required.

- Design, validate, and document work procedures, manufacturing instructions, routings, and associated process documentation required for successful ownership at SOP and sustaining for Optimus Actuators lines

- Develop and optimize line layouts, material flow, waste reduction, and ergonomics using Lean Manufacturing best practices

- Lead root-cause analysis of complex electromechanical systems and mitigate failure modes through a systems approach applying structured problem-solving techniques such as DMAIC, Ishikawa, Five Why (5-Why), and Eight Disciplines (8D) to drive permanent corrective actions

- Analyze and optimize production processes to ensure safety while maximizing Overall Equipment Effectiveness (OEE), throughput, and world-class quality in a cost-effective manner

- Lead non-conforming material (NCM) activities, including documentation, containment, troubleshooting of line fallout, and rework process development

- Monitor and reduce process variation using Statistical Process Control (SPC), Measurement Systems Analysis (MSA), and process capability methods (Cpk/Ppk)

- Collaborate with Equipment, Quality, Controls, and Design Engineering on process validation, control plans, PFMEA inputs, safety procedures, sequence of operations, and production readiness; ensure processes are feasible, capable, and ready for high-volume production

- Provide Design for Manufacturability (DFM) and poka-yoke feedback; eliminate process risk through design and process recommendations

- Define associate staffing levels required to support automated Actuators operations and create recruitment timelines; own responsibility for production associates assigned to the process where required

- Support 24/7 production operations, including flexible hours during launch, ramp, and critical quality or yield events as business needs require

- Degree in Mechanical, Industrial, Electrical, Mechatronics, Manufacturing Engineering, Mathematics, Physical Science, or related field, or equivalent relevant experience

- 5+ years of experience developing and improving high-volume manufacturing processes, with a demonstrated track record of OEE, yield, or process-capability improvement

- Background in automated systems (electronics, computer controls, electromechanical assembly, fastening, and/or IT/MES systems) preferred to support End-of-Line (EOL) troubleshooting

- Experience with Design for Manufacturability (DFM), poka-yoke, and risk elimination through design and process recommendations

- Working knowledge of Bill of Materials (BOM), Manufacturing Execution Systems (MES), specification management, and change-point management

- Familiarity with PFMEA, control plans, SPC, MSA, and process capability (Cpk/Ppk)

- Proficiency with structured problem-solving (DMAIC, Ishikawa, 5-Why, 8D) and data analysis tools; Linux, Tableau, and Minitab experience preferred

- Experience programming in Python, C, C++, or SQL preferred for data extraction, automation, and analysis

- Strong cross-functional communication skills; able to work effectively with Production, Quality, Equipment, Controls, NPI, and Design under changing priorities

- Ability to work hands-on on the factory floor and support flexible hours, including 24/7 operations coverage during launch, ramp, and critical events

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)