Sr. Manufacturing Process Engineer, Robotics

What To Expect
The Sr. Manufacturing Process Engineer, Robotics, leads process design and industrialization efforts that deliver exceptional product quality and volumes for next-generation electric motors manufacturing. You will collaborate closely with cross-functional teams—including design engineering, die engineering, tooling suppliers, quality, automation, and operations—to improve throughput, reduce scrap and downtime, and ensure processes meet Tesla’s rigorous standards for performance, safety, and sustainability. This position blends advanced stamping expertise, materials science for electrical steels, tooling/process optimization, automation integration, and data-driven continuous improvement in a fast-paced, high-volume manufacturing environment.

What You'll Do

Develop, qualify, and optimize high-speed stamping processes (progressive, compound, or hybrid dies) for electric motor laminations from electrical steel coil, ensuring precise geometry, flatness, edge quality, and coating integrity to maximize motor efficiency and minimize core losses

Specify, design/review, validate, and industrialize dies, tooling, press parameters, lubrication, strip feeding, and material handling systems tailored to electrical steels (silicon steels and advanced grades)

Integrate and optimize automation elements—including robotics, PLCs, sensors, vision systems, servo/VFD controls, and end-of-line stacking/bonding equipment—to achieve high throughput, consistent quality inspection, and automated lamination stacking or interlocking

Troubleshoot process, tooling, press, and automation issues on the production floor; lead root-cause analysis (RCA) and implement permanent corrective actions to minimize downtime and scrap

Partner with product design, die engineering, tooling suppliers, quality, and maintenance teams on Design for Manufacturability (DFM), Design for Assembly (DFA), equipment validation (IQ/OQ/PQ), process capability (Cpk), and industrialization of new motor designs and production lines

Drive continuous improvement initiatives using Lean Manufacturing, Six Sigma, and advanced methods—such as predictive maintenance, energy-efficient press operation, scrap reduction/recycling of electrical steel, and waste minimization—aligned with Tesla’s sustainability goals

Support new product introduction (NPI) and production ramp-up by transferring processes into manufacturing, training operators/technicians, and ensuring robust, scalable workflows

Ensure full compliance with safety standards (including safety PLCs and fail-safe systems), quality systems, regulatory requirements, and environmental goals throughout process and equipment lifecycle

What You'll Bring

Degree in Mechanical Engineering, Manufacturing Engineering, or equivalent experience

5 years of experience in manufacturing process engineering within high-volume production environments, preferably automotive, electric motors, precision metal stamping, or electrical steel/component manufacturing. Senior-level ownership of process development and industrialization is expected

Proven expertise in high-speed stamping and metal forming processes for motor laminations or similar precision components, including progressive/compound die design and operation, press setup/controls (mechanical, hydraulic, or servo), coil feeding, and material science of electrical steels (e.g., silicon content, coatings, magnetic properties, grain orientation, and processing effects)

Strong proficiency with process and tooling tools/software: CAD/CAM (SolidWorks, AutoCAD, or equivalent), die design/review, stamping process simulation, PLCs (Allen-Bradley, Siemens, etc.), robotics (Fanuc, KUKA, or similar), vision systems for quality inspection, and industrial communication protocols (EtherCAT, Profinet, etc.)

Demonstrated ability to perform data analysis, statistical process control, root-cause analysis, and continuous improvement using Lean Manufacturing, Six Sigma (Green/Black Belt preferred), DOE, and tools such as Minitab or equivalent

Knowledge of secondary lamination processes (stacking, interlocking, bonding, welding) and quality metrology (dimensional, optical, coating, and ideally magnetic property evaluation) is highly desirable

Excellent problem-solving skills with a hands-on approach to debugging complex process and equipment issues in a production setting

Ability to work in a fast-paced, dynamic environment with occasional overtime or shift work to support 24/7 manufacturing

Travel as required for equipment/die supplier visits, trials or buyoffs (>5%)

Benefits
Compensation and Benefits
Along 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 deduction

Family-building, fertility, adoption and surrogacy benefits

Dental (including orthodontic coverage) and vision plans, both have options with a $0 paycheck contribution

Company Paid (Health Savings Accounts) HSA Contribution when enrolled in the High-Deductible medical plan with HSA

Healthcare and Dependent Care Flexible Spending Accounts (FSA)

401(k) with employer match, Employee Stock Purchase Plans, and other financial benefits

Company paid Basic Life, AD&D

Short-term and long-term disability insurance (90 day waiting period)

Employee Assistance Program

Sick and Vacation time (Flex time for salary positions, Accrued hours for Hourly positions), and Paid Holidays

Back-up childcare and parenting support resources

Voluntary benefits to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance

Weight Loss and Tobacco Cessation Programs

Tesla Babies program

Commuter benefits

Employee discounts and perks program

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