Process Engineer

Role overview

This position focuses on sustaining and improving manufacturing processes for Service Manufacturing lines that build high-voltage batteries and electric motors for Tesla’s service network. The role centers on lean manufacturing, quality improvement, troubleshooting, and cross-functional coordination to raise yield, reduce fallout, and strengthen process controls.

Key duties

• Drive ongoing improvement work aimed at safety, quality, output, and cost metrics.
• Set up routine yield monitoring, including data capture and Pareto analysis of major failure modes, then run team discussions to implement corrective actions.
• Build and maintain SPC systems for all critical process variables and keep process documentation accurate, clear, and current.
• Partner with New Product Introduction teams to test and roll out product updates and plan for supplier sub-component obsolescence.
• Work alongside maintenance and equipment engineering teams to diagnose equipment problems and resolve production disruptions.
• Own non-conforming material activities, including documenting and investigating line fallout.
• Develop troubleshooting references and formal procedures for offline failure analysis of test issues and non-conformances.
• Create, validate, and document rework methods for non-conforming material.
• Coordinate with field quality and remanufacturing teams to track product reliability in the field and implement process improvements that reduce failures.
• Maintain SOPs and process flows, updating them as process changes and BoM revisions occur.

Requirements

• A degree in engineering is preferred, ideally in Mechanical, Electrical, Manufacturing, or Industrial Engineering, though comparable hands-on experience may be accepted.
• At least 2 years of experience in manufacturing, operations, or a similar environment.
• Exposure to lean manufacturing, 5S, continuous improvement, and structured problem-solving methods such as A3 or 8D.
• Practical knowledge of FMEA, 8D, and statistical process control.
• Experience with time studies, industrial engineering fundamentals, and strong mechanical/electrical engineering basics.
• Working familiarity with Python, SQL, and/or SolidWorks.
• Strong communication skills, both written and verbal, plus the ability to collaborate in large teams and operate comfortably in ambiguous situations.

Benefits

• Competitive compensation with full-time employee benefits available from day one.
• Medical coverage with plan options that include $0 payroll deduction.
• Family-building support, including fertility, adoption, and surrogacy benefits.
• Dental and vision plans with options that require $0 paycheck contribution, including orthodontic coverage.
• Employer HSA contribution when enrolled in the high-deductible medical plan with HSA.
• Healthcare and dependent care FSA options.
• 401(k) with employer match, employee stock purchase plans, and other financial benefits.
• Company-paid basic life and AD&D insurance.
• Short-term and long-term disability insurance with a 90-day waiting period.
• Employee assistance program.
• Sick time, vacation time, and paid holidays.
• Back-up childcare and parenting support resources.
• Voluntary coverage options such as critical illness, hospital indemnity, accident, theft and legal services, and pet insurance.
• Weight loss and tobacco cessation programs.
• Tesla Babies program.
• Commuter benefits.
• Employee discounts and perks program.

Compensation

The posted pay range for this role depends on level:

• Associate Process Engineer: $75,600 to $113,400 per year
• Process Engineer: $93,600 to $140,400 per year
• Sr Process Engineer: $108,000 to $162,000 per year

Total compensation may also include cash and stock awards, along with benefits. Final pay can vary based on location, role level, job-related knowledge, skills, and experience.

Additional notes

The role reports to the engineering lead for the relevant Service Manufacturing product. Daily work involves close coordination with Manufacturing Engineering, New Product Introduction, Quality Engineering, Equipment Engineering, and Production Operators. Strong interpersonal ability is important because the role includes frequent collaboration and regular interaction across teams. There is also a strong emphasis on troubleshooting test failures, collecting data, developing rework processes, and learning from remanufacturing operations to reduce defects and field failures.