Sr. Manufacturing Engineer, Line Design, Optimus

About the role

Sr. Manufacturing Engineer, Line Design, Optimus | Tesla (Manufacturing)

Location: Austin, Texas | Req ID: 270198 | Job Type: Full-time

What to Expect

The Castings Manufacturing Engineering Group is the part of the Materials Engineering Group responsible for the design, build, launch and handover of state of the art Casting lines and equipment currently used for vehicle and humanoid programs. This team is focusing on achieving the highest efficiency, manufacturing volume and safety while proving performance and documenting every aspect of the project for handover to sustaining.

A successful candidate for this role will have technical knowledge in high volume die casting manufacturing lines and new technology introduction. The candidate must have experience analyzing manufacturing requirements and transforming them into efficient detailed designs that are robust and executable. You will own specialized equipment from beginning to end defining performance requirements, performing simulations as needed to verify and align with first principles solutions and owning the commissioning including final validation.

What You'll Do

• Lead manufacturing casting and trim cell design and launch, applying a first-principles approach to develop efficient, high-capacity layouts that optimize factory space
• Conduct initial layout studies and material flow, develop bid packages and vendor selection, and coordinate building utilities
• Create equipment concept designs and lead vendor design reviews while overseeing fabrication, acceptance testing, and equipment installation
• Design custom fixtures, jigs, tools, structures, etc. as needed, providing supporting design validation analysis (FMEA, FEA, CFD, etc.) and detailed build to print models/drawings for fabrication
• Implementing and managing continuous process optimization including the addition of advanced and conventional technologies to improve quality, productivity and reduce overall waste
• Specify and lay-out equipment for high pressure die casting shops, from melt through trim, including all ancillary items required to operate the cell
• Establish operational performance metrics for casting and trimming operations and then verify material flow within the design to avoid blocking and starvation
• Create and manage large, detailed 3D Cad layouts used to locate equipment, support utilities, create utility routings, and support virtual commissioning
• Oversee technical and schedule performance of equipment suppliers following Tesla standards and project roadmap
• Create documentation needed to sustain operation of the equipment (e.g.  start up and shut down procedures, operation instructions, KPI’s, troubleshooting manuals, maintenance schedules, assembly drawings with BOM, fabrication drawings)

What You'll Bring

• Degree in Manufacturing Engineering, Mechanical engineering, or related field, or equivalent experience
• Die casting background strongly preferred
• 5+ years of experience designing manufacturing lines, mechanical equipment, fixturing and tooling in 2D and 3D CAD (SolidWorks/Catia/Siemens NX/Revit/AutoCAD or similar)
• Competence in ISO 12100 Safety Standards for risk assessment and safety of machinery
• Experience in machine safety: ANSI B11, RIA R15.06, ISO 13849
• Experience in simulation to validate design meets operational requirements (FEA, CFD, Transient Thermal)
• Experience introducing new high pressure die casting equipment and new processes into a production environment from conceptual design throughout start up preferred
• Experience with industrial automation using robotic material handling and casting conveyance
• Proven project management experience of $1M+ capex projects with cost benefit analysis development
• Strong verbal and written communication skills able to lead technical reviews