Senior Process Engineer – Energy Remanufacturing

About the role

The Senior Process Engineer will drive the development, implementation, and optimisation of production methodologies for Energy Remanufacturing at Tesla. You will lead cross‑functional initiatives that improve product flow, reduce waste, and enhance overall equipment effectiveness while mentoring junior engineers.

Key responsibilities

• Lead cross‑functional teams to create Process Flows, Control Plans, GR&R, work instructions, and rework procedures.
• Develop and qualify tools, calibrations, and quality validation methods.
• Perform risk assessments (PFMEA) and support New Product Introduction (NPI).
• Collaborate with Original Equipment Manufacturers to commission new automated equipment.
• Partner with EHS to identify and mitigate safety hazards.
• Design and implement mentorship programs for junior engineers.
• Analyse line layouts, material flow, waste reduction, and ergonomics using Lean Manufacturing principles.
• Transition products from concept to pilot line and mass production, creating reliable documentation.
• Optimise processes to maximise OEE, yield, capacity, and cost‑effectiveness.
• Lead continuous‑improvement projects and provide clear reporting to senior management.
• Collect, visualise, and analyse production data to support operational and financial decisions.

Required profile

• Senior‑level experience in manufacturing process engineering.
• Proven ability to lead cross‑functional teams and mentor junior engineers.
• Strong background in Lean Manufacturing, Six Sigma, Kaizen, and Gemba practices.
• Experience with tool/fixture selection, line layout design, and ergonomic studies.
• Familiarity with NPI, quality validation, and PFMEA risk assessments.
• Data‑driven mindset with solid analytical skills.

Required skills

• Six Sigma
• Lean Manufacturing
• PFMEA (Process Failure Mode Effects Analysis)
• Process capability analysis
• Control plan development
• GR&R (Gauge Repeatability & Reproducibility)
• Calibration and qualification of tools
• OEE (Overall Equipment Effectiveness) optimisation
• Data analysis and visualization
• 5S, Kaizen, Gemba