Site Manager - Automotive BIW Automation Project (LHD, RHD & RUB Lines)

Company Description BWS represents leading European expertise in industrial production equipment installation.

Location: Fremont, California, USA (100% On-site)

Project Duration: Contract / Project-based (Immediate start: October 2026 – Completion: January 2027; 62-day intensive execution window)

Industry: Automotive Manufacturing – Body in White (BIW)

Company Description BWS represents leading European expertise in industrial production equipment installation.

Location: Fremont, California, USA (100% On-site)

Project Duration: Contract / Project-based (Immediate start: October 2026 – Completion: January 2027; 62-day intensive execution window)

Industry: Automotive Manufacturing – Body in White (BIW)

Position Overview
We are seeking a seasoned BIW Site Manager to lead the on-site construction, mechanical/electrical installation, and commissioning/debugging phases for the BL5 Tooling Upgrade Project (LHD, RHD, and RUB cells) at the Tesla Fremont Factory. Acting as the primary on-site authority between our installation/commissioning teams, the engineering partner, and the end client (Tesla), you will ensure all demolition, equipment relocation, new line installation, and quality validations are executed safely, on schedule, and strictly aligned with Tesla EHS and technical buyoff standards.

Key Responsibilities

End-to-End Site & Construction Management: Direct mechanical and electrical crews across brownfield demolition/relocation and new line installation: positioning and anchoring 18 new KUKA robots and risers, turntables, GEO/reweld fixtures, grippers, safety fencing, cable trays, and rigid/flexible utility piping (water/air manifolds, water savers, and main tie-ins).

Commissioning & Debug Oversight: Coordinate PLC and Robot debugging teams across LHD (8 robots), RHD (8 robots), and RUB (2 robots) zones covering GEO Spot Welding, Adhesive Dispensing/Sealing (SCA), Material Handling, and Automated Bolting systems.

Technical Validation & Calibration: Ensure commissioning teams properly execute KUKA EMD zero-point mastering, servo welding gun pressure and current calibrations (using force gauges and current testers), SafeMove configurations, and PLC/robot interference zone validations between new and existing production lines.

Execution of Tesla Milestone Buyoffs: Drive sequential completion of all required customer handover protocols:

STATUS-220 (Power On): Electrical Acceptance Checklist (TS-0018282) and EHS Buyoff Checklist (TS-0011667).

STATUS-240 & 250: Offline program downloads, network communication tests, functional verification of safety devices (light curtains, area laser scanners, safety gate locks, finger-swipes), and 250 Safety Buyoff (TS-0011569).

STATUS-260 & 270: Manual Mode (T1) debug, HMI & I/O checks, Joint Validation #1, and KUKA Safety Buyoff (TS-0010610).

STATUS-280, 290 & Ramp-Up: Auto Mode debug, Joint Validation #2, Line Dry Cycle, Manufacturing Quality Builds (#1, #2, #3), Takt Time optimization, and open issue closure to achieve SOP on January 5, 2027.

Schedule, EHS & Stakeholder Control: Manage the 62-day critical path schedule across holiday shutdown windows (Oct 26, 2026 – Jan 5, 2027), enforce zero-incident EHS compliance, lead daily alignment meetings with Tesla Manufacturing Engineering, and provide daily executive progress reports.

Qualifications & Requirements

Experience: 5–8+ years of proven experience as a Site Manager, Construction Manager, or Installation & Commissioning Lead in automotive Body in White (BIW) automated assembly lines.

Technical Proficiency: Strong working knowledge of mechanical rigging/anchoring, industrial electrical panels (PDP, WDP, MCP, SVP, Mantis), Profinet/Ethernet architectures, pneumatic/cooling manifolds, and KUKA robotics integration.

OEM Standards: Prior on-site experience at Tesla facilities (direct familiarity with Tesla STATUS 220–290 buyoff procedures and TS checklists is highly preferred) or equivalent tier-1 automotive OEMs.

Certifications & Work Authorization: Active OSHA 30 certification. Must hold valid, unrestricted legal authorization to work in the United States.

Languages: Professional fluency in English is mandatory; proficiency in Spanish and/or Mandarin Chinese is a strong asset for cross-functional team coordination.

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