Process Engineer, Powdercoat, Megapack

About the role

• Process Engineer, Powdercoat, Megapack | Tesla (Manufacturing)
• Location: Brookshire, Texas | Req ID: 286258 | Job Type: Full-time
• What to Expect

The Process Engineer will implement, develop, and optimize coatings application & surface preparations/treatment/laser in the manufacturing operations of Tesla. This engineer will be responsible for optimizing product flow through the factory through process optimization that may include tool /fixture selection, line layouts, ergonomic study, material presentation, cycle time optimization and other relevant factors.

They will interface design, test, and material engineering to solve problems, improve manufacturability, and implement continual improvement. They will sustain products with cost reduction and yield improvements. In addition, the Process Engineer will work with quality to compile and evaluate data to determine appropriate limits and variables for process or material specifications.

What You'll Do

• Expertise in coating application process development and process capability studies through critical data analysis and deep product understanding
• Develop and modify line layouts (material flow, waste reduction, ergonomics) using Lean Manufacturing best practices; lead product transition from concept to pilot line to mass manufacturing
• Analyze and optimize coating application processes to ensure safety, maximize OEE, drive cost-effectiveness, and achieve world-class quality; champion continuous improvement projects for yield, capacity, and capability
• Diagnose coating process issues and drive corrective actions to root cause elimination using structured problem-solving (DMAIC, Ishikawa, 5-Why, 8D)
• Analyze data from multiple sources to identify trends in build quality and efficiency; develop robust data collection, visualization, and analysis tools; enable data-driven operational and financial decisions via predictive insights into tool/process performance, including factory data system integration and tools such as MySQL, Python, R, JMP, Minitab, Tableau, and Ignition
• Support engineering and manufacturing with 5S, Lean activities, material handling improvements, production line configuration, and safety procedures
• Monitor and reduce process variation using SPC and Measurement Systems Analysis; audit manufacturing processes to ensure adherence to product specifications and standards
• Participate in development and maintenance of FMEAs and Control Plans; analyze, develop, process, and implement Engineering Change Orders
• Create and maintain Manufacturing Instructions, routings, and associated processes; develop/train sustaining technicians and operators; manage process sustaining technicians for day-to-day production coverage, including rework procedure development and documentation
• Support 24/7 production operations

What You'll Bring

• Degree in Engineering, Chemistry, Polymer Science, Materials Science, Chemical Engineering, or equivalent experience
• Hands-on working experience with powder or liquid paint supply systems, mechanical treatment or chemical pretreatment processes, sealant/glue dispensing, and laser abrasion
• Strong foundation in organic chemistry, polymer chemistry, materials science, and surface preparation as applied to coating systems
• Proven experience developing and improving coatings application processes with a demonstrated track record of Overall Equipment Effectiveness improvement activities
• Strong problem-solving skills and aptitude for learning systems quickly; proficient in structured problem-solving techniques including DMAIC, Ishikawa, Five Why, and Eight Disciplines
• Ability to resolve high-level performance issues into addressable actions and develop data-driven root cause analyses and solutions
• Solid knowledge and practical application of Statistical Process Control
• Exceptional capacity for managing simultaneous activities, competing priorities, and challenges
• Strong ability to work and communicate effectively with teams, suppliers, and peers within a manufacturing and engineering organization
• Creative capacity for developing new ways to do things better, cheaper, and faster, in alignment with the Tesla approach to revolutionary product development

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)