Process Engineer

The Castings / RPC Process Engineer sustains, optimizes, and redesigns manufacturing processes, tools, and fixtures in a hands-on production environment operating 24/7 across 4 shifts to achieve Safety, Quality, Delivery, and Cost targets. This role leads projects to identify inefficiencies in casting operations, applies lean manufacturing principles and kaizen methodologies for cost reduction and productivity gains, develops standardized work procedures ensuring consistency, quality, compliance, logistics, material flow, cost analysis, and production coordination, and conducts FMEA risk assessments alongside statistical analyses to set processes, staff requirements, production standards, and mitigation strategies. The engineer manages process changes for smooth transitions with minimal disruption, updates CAD layouts and designs efficient equipment, material, and workspace configurations, optimizes cycle times, mod-aps, ergonomics, OEE, capability, and line utilization through data-driven monitoring and corrective actions, and collaborates with engineering, production, and management teams as the process leader to align on operational efficiency and goals.

• Analyze, design, and optimize production processes for safety, yield, capacity, and cost-effectiveness
• Develop and modify line layouts, processes, and fixtures using Lean Manufacturing to improve flow, reduce waste, and enhance ergonomics
• Support product transitions from concept to pilot and mass production
• Partner with Equipment Engineering to balance cycle times with workforce needs
• Manage internal maintenance and major contractor projects
• Assist Maintenance in troubleshooting breakdowns and chronic failures
• Define project scope, budgets, vendor coordination, and equipment installations
• Recommend design and assembly improvements to enhance manufacturability
• Train supervisors and operators as needed
• Collaborate on off-hours improvements in cycle time, uptime, quality, and safety

• Degree in Industrial, Process, Manufacturing or other engineering discipline, or equivalent experience
• 3+ years of experience designing, implementing, and optimizing process equipment, tools, fixtures, and instructions
• Demonstrated experience developing/improving processes with a track record of Overall Equipment Effectiveness (OEE) improvements
• Experience ramping high-volume, automated, and semi-automated manufacturing lines
• Strong mechanical intuition, hands-on experience modifying jigs/fixtures, equipment installations, interpreting mechanical drawings (CNC/manual machining beneficial)
• Proficiency in AUTOCAD/factory layout tools; experience with Vision inspection systems (Keyence 2D/profilometry), Ignition Automation, MES, and/or Python highly desired
• Solid knowledge of BOMs, manufacturability, process design/validation, assembly methods, design reviews, cost reduction, and statistics
• Experience applying Lean Six Sigma methodologies (Waste Reduction, Poka-Yoke, SPC, GR&R, DOE)
• Strong ability to work and communicate effectively with teams/peers in manufacturing/engineering, excellent written/verbal skills
• Excellent project management, prioritization, and ability to simplify complex problems while influencing stakeholders, with the capacity for managing simultaneous activities and challenges

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

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.