Manufacturing Joining Engineer, Closures

Manufacturing Joining EngineerTesla is seeking a highly motivated and experienced Manufacturing Joining Engineer to join our Closures team supporting NV93 GA Closures. As the plasma, 2K dispense, bonding, and vision specialist, you will own process health, equipment performance, and continuous improvement for automated joining of plastic closure assemblies. You will maintain and improve existing processes, tooling, and robotic cells, and partner with cross-functional teams to remove bottlenecks and raise line performance.ResponsibilitiesServe as the subject matter expert for plasma surface treatment, SCA dispensing 2K, structural bonding, and vision systems (Coherix + Mech Mind) across NV93 GA ClosuresOwn day-to-day process stability for plasma treatment quality, 2K mix/bead/path control, bonded-joint integrity, and in-process vision (Coherix bead/Z-tracking and Mech Mind 3D)Perform root cause analysis on complex joining faults (plasma coverage/dyne, mix ratio, open time, wet-out, adhesion vs cohesive failure, bead geometry, compression/fit-up, vision false rejects) using DMAIC, Ishikawa, Five Why (5W), and Eight Disciplines (8D), and drive permanent corrective actionsLead production trials to optimize plasma, 2K dispense, and bonding parameters, introduce new product designs, and validate process windows on plastic-to-plastic and plastic-to-metal jointsAnalyze production processes to ensure safety while maximizing Overall Equipment Effectiveness (OEE); optimize cycle time, balance workloads, and reduce bottlenecks in plasma, dispense, bonding, and vision stationsLead non-conforming material (NCM) activities, including rework procedures, containment, and line fallout troubleshooting for bonded closures; support manufacturing excellence (5S, Lean, material handling, line layout)Monitor and reduce process variation using SPC and Measurement Systems Analysis (MSA), including dyne/surface energy, bead volume/height, teardown CF%, max defect length, and vision system capabilityDevelop and maintain process sheets, PFMEAs, control plans, and standard operating procedures for plasma, 2K dispense, bonding, and visionApply GD&T and plastics manufacturing knowledge to diagnose fit-up, gap, compression, locator, and dimensional stack-up issues that drive bond quality on molded closure assembliesPartner with Controls, Maintenance, Quality, Materials, and equipment vendors (SCA, Coherix, Mech Mind, plasma OEMs) on upgrades, spare strategy, and technical escalationsRequirementsDegree in Mechanical, Mechatronics, Automotive, Manufacturing, Materials/Polymer, or equivalent experienceBackground in plastics manufacturing processes required (injection molding, dimensional stability, surface energy, primer/adhesion promoters, thermal expansion of plastic assemblies)Background in Geometric Dimensioning and Tolerancing (GD&T) required4+ years developing and improving high-volume manufacturing processes; at least 2+ years hands-on in plasma treatment, 2K adhesive dispensing, and/or structural bonding of plastic assemblies in automated/robotic environmentsStrong knowledge of plasma fundamentals (surface energy, dyne, treatment distance/speed/power, coverage), 2K dispense (mix ratio, pot life/open time, bead path, volume/height control), bonding (wet-out, compression, cure, cohesive vs adhesive failure, tensile/peel), 3D vision (Coherix / Mech Mind), and joining quality gates (teardown CF%, max single-defect length)Ability to initiate design and process changes using DfM, Poka-Yoke, and failure-mode eliminationStrong understanding of BOM, MES, quality specifications, process capability (Cpk), and change managementAbility to use structured problem-solving (DMAIC, Ishikawa, 5W, 8D) and to collaborate with cross-functional teams on highly technical problemsExcellent written and verbal communication skillsLinux, Tableau, SQL, Ignition, and/or Minitab experience preferred; exposure to other Closures joining technologies (ultrasonic spot weld, 1K urethane/SCA SG10, Robotape, sealing) is a plusCompensation & 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