Sr. Manufacturing Engineer, Machining, Optimus

Tesla's Manufacturing Engineering team is at the forefront of developing first-of-a-kind processes which allow us to produce amazing vehicles at best-in-class quality and rate, in a safe and ergonomic environment. We are seeking a Sr Manufacturing Engineer – Machining to lead the design and development of precision machining processes used in the manufacture of our products. This includes process specification and validation, establishing and optimizing critical machining parameters, design for manufacturability, equipment specification and design, as well as installation and commissioning. The candidate will work closely with internal cross-functional teams, external vendors, and technology partners on machining process development from concept to production. This position requires up to 25% travel.

Responsibilities

Lead cross-functional collaboration and build relationships across the organization through coordination with other process, equipment, mechanical, electrical, and support disciplines including project managers, manufacturing reps, and other stakeholders Document product requirements for machining process and equipment specification, and perform detailed line design based on process requirements, throughput targets, cycle time analysis, and OEE calculations Analyze and understand the cost of a process per unit of production and drive development of processes which will yield the greatest benefit Lead product design for manufacturability (DFM) and sustainability, including analysis of product design and identification of potential risks to the machining process and steering product design to the lowest overall cost (BOM cost + manufacturing cost) Develop machining technologies and equipment from concept to serial production, including CNC milling, turning, drilling, boring, grinding, and multi-axis operations Define and optimize cutting parameters (speeds, feeds, depths of cut, tool paths) to achieve target dimensional tolerances, surface finishes, and tool life Select, qualify, and manage cutting tools, workholding fixtures, and coolant/lubrication systems and develop and maintain machining process documentation including setup sheets, control plans, and standard work instructions Lead process qualification, including development of acceptance testing criteria and verification that process/equipment meets requirements using statistical tools (such as GR&R, SPC, and Cp/Cpk) Manage large-scale projects for new programs, including the development of timing plans and cost breakdowns for executive approval, identification of risks to project timing driving corrective action, reporting of project status to the executive team, and oversight of installation and commissioning of new machining lines Drive continuous improvement of existing machining processes to improve quality, reduce cycle time, increase tool life, and lower cost per part

Requirements

Degree in Manufacturing, Mechanical, or Industrial Engineering with 5+ years of related experience in a technology-based industry where CNC machining and automated methods are utilized in the production of precision components, or equivalent experience Deep knowledge of CNC machining processes including milling, turning, drilling, grinding, and multi-axis machining of metals (aluminum, steel, cast iron, titanium, etc.) and engineered materials Experience with CNC programming (G-code / M-code) and CAM software (MasterCAM, NX CAM, PowerMill) Experience with developing, installing, and commissioning high-volume machining equipment and automation systems (CNC machining centers, lathes, transfer lines, robotic load/unload, in-process gauging, chip/coolant management systems) Strong understanding of GD&T, metrology, and inspection methods (CMM, surface profilometry, in-process gauging) Experience in developing, executing, and interpreting results of Design of Experiments (DOE) for machining parameter optimization Experience using Industrial Engineering methods working in high-volume manufacturing processes Proficient in CAD software such as CATIA, SolidWorks, Inventor, and/or AutoCAD and mastery of MS Office suite, Confluence, Jira, etc. Proficient in the development and deployment of PFMEAs; new product introduction and manufacturing operations experience desired Travel required ~25%