Process Engineer, Battery Module

4 Months ago • 3-5 Years • Software Development & Engineering

Job Summary

Job Description

Tesla's Battery Process Engineering team seeks a highly motivated Process Engineer with laser welding experience for its Gigafactory in Berlin-Brandenburg. Responsibilities include commissioning and ramping high-speed automated equipment, ensuring efficient and safe production lines, troubleshooting and improving processes, building training materials, and managing equipment life cycle. The role requires expertise in laser welding systems, statistical data analysis, PLC/HMI software, and root cause analysis. The engineer will collaborate with cross-functional teams, third-party suppliers, and internal teams to optimize manufacturing processes, improve OEE metrics (yield, cycle time, availability, cost), and implement continuous improvement initiatives. Experience with 3D CAD and PLC programming is beneficial.
Must have:
  • Laser welding experience
  • High-volume manufacturing experience
  • Root cause analysis skills
  • PLC/HMI software knowledge
  • Statistical data analysis
  • 3-5 years relevant experience
Good to have:
  • 3D CAD design experience
  • PLC programming experience
  • JMP software experience
  • Battery module technology knowledge

Job Details

What to Expect

Tesla’s world-class Battery Process Engineering team is looking for a highly-motivated Process Engineer with experience in laser welding applications for an exciting new project.  This engineer is expected to be or become a Process/manufacturing expert in the field of laser welding applications and will be involved in the design, development, commissioning and ramping of high-speed automated equipment, while working in a cross-functional team to test, validate, and roll-out process and product design changes. 

The battery cell is a critical component in Tesla vehicles and storage systems. This role will have the opportunity to make meaningful contributions to our products.  The work environment is demanding, fast-paced and incredibly exciting.  The ideal candidate should be ready to push their limits, as they join in highly motivated and capable team to make unbelieveable things into reality.

What You’ll Do
  • Drive Commissioning, and ramp of manufacturing equipment including but not limited to laser welding systems used in custom high speed automated manufacturing equipment and qualify them using statistically valid data sets and workflow
  • Work collaboratively as the equipment expert to ensure production lines run in a safe, efficient manner producing high quality parts
  • Become owner / subject matter expert to drive equipment-related process improvement including detailed troubleshooting and root cause analysis
  • Drive manufacturing ramp by characterizing baseline and improving performance of equipment with laser weld systems; ensure manufacturing lines meet OEE goals
  • Troubleshoot and recover processes using PLC, HMI, or tool management software, and implement changes/improvements
  • Build training material, maintenance routines, and related documentation for equipment life cycle management
  • Lead safety and ergonomic improvements to production equipment which meets or exceeds regulations or best practices
  • Identify equipment critical spare parts and ensure sufficient coverage to prevent extended downtime situations
  • Provide direction and mentorship to third party machine/automation suppliers and/or Tesla internal machine building team; participate in supplier/internal equipment FAT and SAT
  • Develop and manage FMEA / risk assessments to prioritize equipment improvement projects and ensure sufficient repair strategies
  • Review critical process metrics daily for statistical shifts from nominal and develop game plans to address
  • Identify and/or develop critical process monitors and metrics for battery module and pack manufacturing. Use to diagnose issues found during the manufacturing process, efficiently identify root cause, react (but also plan proactively)
  • Guide and develop roadmaps for aggressive improvement to OEE metrics: Yield, Cycle Time, Availability, and Cost. Report metrics to upper management
  • Manage workload with a positive attitude as a team player in a collaborative work environment
  • Drive continuous improvement and support activities for engineering and manufacturing including 5S and Lean manufacturing activities, material handling improvements, production line configuration, and safety procedures
What You’ll Bring
  • Degree in Mechanical, Mechatronics Engineering or another Engineering discipline, with 3 to 5 years of relevant experience in a high volume manufacturing environment, or equivalent experience
  • Experience in equipment using laser welding, materials and vision systems.  Strong hands-on experience with pilot and high-volume manufacturing including practical knowledge in selection of related hardware and software
  • Demonstrated experience solving complex automation and software system issues with limited documentation to debug, build process know-how, and kick off improvement projects
  • Strong understanding of engineering fundamentals and ability to apply them towards manufacturing process development
  • Structured thinking and problem solving abilities. Proven through a number of root cause analysis following a data driven approach, statistical software (JMP) a plus
  • 3D CAD design experience in production equipment, creating/validating layouts, tooling drawings, pneumatic and electrical schematics.  Experience with PLC programming a plus
  • Availability for travel domestic/international as required; knowledge and understanding of Battery module technology a plus

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