Lab Failure Analysis Engineer, LFP Cell Manufacturing

The Failure Analysis team’s mission is to determine root cause and contributing factors that improve the experience of Tesla’s energy products by reducing manufacturing quality defects and issues. This individual contributor role supports LFP cell manufacturing, partners with a broad cross-functional team including engineering, production, manufacturing, and reliability, and carries high internal visibility. It requires extensive hands-on failure analysis and root-cause work at both the subassembly and component level and the finished-product level. We are looking for a multi-faceted engineer who will identify quality risks and issues throughout cell manufacturing, lead 8D problem solving, drive corrective actions, and implement countermeasures. To be effective, the engineer must be intimately familiar with the detailed behavior of these electromechanical components and with the tools and equipment used in their design and manufacture, and will work with partner teams to root-cause manufacturing defects and implement countermeasures that improve quality, reliability, and durability.

- Investigate manufacturing quality defects to identify root cause and contributing factors
- Lead structured problem solving, including 8D, fishbone, and Six Sigma, and drive corrective actions to closure
- Perform hands-on product teardowns, and use machine-shop tools to prepare and section samples
- Use analytical tools including X-ray, CT, optical microscopy, cross-sectioning, thermography, and functional testing
- Apply statistical methods with tools such as Minitab, JMP, Tableau, SPC, and MSA/GR&R to quantify defects and confirm that countermeasures are effective
- Collaborate with engineering, production, manufacturing, reliability, and other partners to resolve identified failure causes
- Feed teardown and failure-analysis lessons into design reviews and DFMEAs to improve yield and reduce quality risk

- Degree in Electrical, Electronics, Mechanical, or Materials Engineering, or equivalent experience
- Deep understanding of cell manufacturing and of problem-solving methods such as 8D, fishbone, and Six Sigma
- Strong, demonstrable hands-on experience with product teardowns and electrical test equipment, including power supplies, multimeters, oscilloscopes, and other common equipment
- Knowledge of failure analysis techniques, including 2D/3D X-ray and CT, metallurgy, FTIR, DSC, SEM, and FLIR thermography
- Familiarity with machine-shop tools, optical microscopes, cross-sectioning tools, and related sample preparation
- Familiarity with statistical data analysis tools and techniques, including Minitab, JMP, Tableau, SPC, and MSA/GR&R
- Must have command of English language both written and verbal