Process Engineer, General Assembly, Megafactory

Process EngineerThe Process Engineer will be responsible for process sustaining and continuous improvement on the production line, building Tesla's commercial scale energy storage product. This position will be responsible for applying lean manufacturing principles to monitor yield, fallout, and critical parameters and drive necessary process improvements. Daily work will be highly cooperative in nature with regularly interactions with manufacturing engineering, new product introduction, quality engineering, equipment engineering, and production operators – strong interpersonal skills are critical. The engineer will place a significant focus on troubleshooting and root causing test failures and fallout, including data collection and rework process development.The Process Engineer should be detail focused with an understanding of the big picture. They must be curious, self-motivated, receptive to feedback, and appreciate an environment where superior work is encouraged, noticed and rewarded.ResponsibilitiesDevelop expertise in manufacturing processes. Understand process capabilities through critical data analysis and in depth understanding of the product. Develop and modify line layouts, including material flow, waste reduction, and ergonomics, utilizing Lean Manufacturing best practices. Participate in the transition of a product from concept to pilot line production and into mass manufacturingRoot Cause analysis of complex systems, and mitigation of failure modes via a systems approachAnalyze and optimize production processes to ensure safety while maximizing Overall Equipment Effectiveness (OEE) in cost effective means while driving to achieve world-class quality levels. Champion continuous improvement projects (CIP) to maximize yield, capacity, and capabilityLead continuous improvement activities to drive improvements to critical KPIs: safety, quality, output, and cost. Establish and monitor SPC for all critical process parameters, then analyze, develop, process, and implement Engineering Change OrdersLead NCM (non-conforming material) activities, including the documentation and troubleshooting of line fall out. Create troubleshooting guides and document procedures for offline failure analysis of test failures and non-conformances. Design, validate, and document rework procedures for non-conforming materialResponsible for diagnosing issues found during the part manufacturing process and drive corrective action back to source, resulting in root cause identification and elimination. Utilize structured problem solving techniques such as DMAIC, Ishikawa, Five Why (5W) and Eight Disciplines (8D)Perform supporting activities for engineering and manufacturing including 5S and Lean manufacturing activities, material handling improvements, production line configuration, and safety proceduresMonitor and reduce process variation using techniques such as Statistical Process Control (SPC) and Measurement Systems Analysis (MSA). Monitor and audit manufacturing processes to ensure product specifications and standards are achieved. Participate in the development and maintenance of FMEAs and Control PlansCreate and maintain Manufacturing Instructions, routings, and associated processes. Develop and train sustaining technicians, assist in the training of operators as needed. Manage activities for process sustaining technicians to support day to day coverage of production line, including developing and documenting appropriate rework proceduresSupport 24 by 7 production operationsRequirementsDegree in Engineering, or equivalent experienceDesign for Manufacturability experience, Poke Yoke, and elimination of risk with design recommendationsBackground in Automated Systems (Electronics, Computer Controls, Electromechanical, Fastening, and/or IT Systems) is preferable to support End of Line (EOL) troubleshootingAccepts challenge readily, and is able to dive deep into learning / applying concepts in areas less familiar or on ambiguous problemsExperience developing and improving Process. Have a demonstrated track record of Overall Equipment Effectiveness improvement activitiesGood understanding of Bill of Materials, Manufacturing Execution System, Specification Management, Change Point ManagementStrong problem solving skills and an aptitude for learning systems quickly. Able to utilize structured problem solving techniques such as DMAIC, Ishikawa, Five Why (5W) or Eight Disciplines (8D). Able to resolve high level performance issues into addressable actions; Knowledge of Statistical Process Control and its applicationStrong ability to work and communicate effectively with team and peers within a manufacturing and engineering organization. This includes excellent communication skills: written and verbalCreative capacity for developing new ways to do things better, cheaper, faster in alignment with the Tesla approach to revolutionary product developmentDemonstrated ability to balance multiple priorities, ability to work in large teams, strong verbal and written communication, and comfortable with ambiguityCompensation & BenefitsAlong 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 deductionFamily-building, fertility, adoption and surrogacy benefitsDental (including orthodontic coverage) and vision plans, both have options with a $0 paycheck contributionCompany Paid (Health Savings Accounts) HSA Contribution when enrolled in the High-Deductible medical plan with HSAHealthcare and Dependent Care Flexible Spending Accounts (FSA)401(k) with employer match, Employee Stock Purchase Plans, and other financial benefitsCompany paid Basic Life, AD&DShort-term and long-term disability insurance (90 day waiting period)Employee Assistance ProgramSick and Vacation time (Flex time for salary positions, Accrued hours for Hourly positions), and Paid HolidaysBack-up childcare and parenting support resourcesVoluntary benefits to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insuranceWeight Loss and Tobacco Cessation ProgramsTesla Babies programCommuter benefitsEmployee discounts and perks program