Supervisor Failure Analysis Cell Field Reliability jobs at Tesla in United States, Fremont

This role is highly engaging, and you will also be working on one of our most exciting products. You will collaborate with cross-functional engineering teams to understand emerging designs and architectures. You will be responsible for identifying risks associated with these architectures. You will identify appropriate stresses that our products must pass and create test plans, which will be used to assess the reliability of our products. You will provide reliability analyses and suggestions to improve the reliability of our products.

• Apply solid knowledge of reliability methods and electro-mechanical chassis, suspension, and steering systems to design accelerated test plans for design validation, burn-in testing, environmental stress screening (ESS), ongoing reliability testing (ORT), and demonstration of reliability growth
• Analyze field usage and environmental conditions to optimize requirement setting and test methods
• Facilitate and lead design FMEA sessions to assess product risks, determine validation test plans and drive reliable design choices
• Work with manufacturing quality, service engineering, supplier quality and design teams to identify root causes and drive resolution for failures originating in testing and in the field
• Generate process validation test plans to implement at suppliers, and drive root cause corrective action with suppliers to resolve production process issues
• Provide reliability design guidelines and apply reliability lessons learned to enable continuous improvement

• Degree in Mechanical Engineering or equivalent experience
• 2+ years of experience working on electro-mechanical systems (including relevant internship or academic lab work experience)
• In-depth understanding of chassis systems and high-level understanding of other vehicle systems like body, exteriors, and closures
• Experience with burn-in testing, Environmental Stress Screening (ESS), Ongoing Reliability Testing (ORT).
• Understanding of Highly Accelerated testing methods and governing equations for different types of acceleration models
• Experience with developing reliability guidelines and inventing novel ways of reliability testing
• Working knowledge of reliability statistics including Weibull analysis, and experience with statistical software such as JMP, Minitab, etc.
• Working knowledge of failure analysis techniques such as optical microscopy, SEM, CSAM, X-ray, cross-sectioning and EDX
• Self-driven and focused individual with a proven ability to manage parallel tasks effectively, with a desire to work in a fast-paced environment
• Proven ability to remain engaged, proactive, and positive in tough circumstances

• Supervision of hourly maintenance technicians. Defining roles and responsibilities and ensuring the team is meeting expectations; providing direction and following-up on execution of work
• Investigate and implement countermeasures to prevent repetitive breakdowns using data
• Collaborate with production leaders and engineers to track and improve line efficiency
• Develop preventative maintenance schedules that drive down MTTR and improve overall shop uptime
• Understand and track the spending across the shops to work with shop leaders and/or internal team to reduce costs
• Maintain and help develop up-to-date maintenance and calibration procedures and schedules
• Develop new maintenance instructions for equipment or equipment changes and provide training to maintenance teams

• Minimum of 2-3 years of maintenance technician management experience in a high-volume manufacturing/industrial environment, military or equivalent experience, with a strong emphasis on torque tooling is preferred
• Skilled at troubleshooting mechanical, electrical, welding, and/or pneumatic systems, and communications networks/systems
• Demonstrated experience with 3-phase 480/208 VAC, single-phase 208/120 VAC, and 24 VDC systems
• Ability to rapidly become proficient in PLC/Soft PLC communications
• Demonstrated ability to use CMMS (Computerized Maintenance-Management Systems) to include monitoring, scheduling, and creating work orders and preventative maintenance schedules
• Must be skilled with common workplace software (MS Word, Excel, Visio, Access)
• Must have command of the English language, both written and verbal

• Work with automation software, databases, virtual machines, and other applications that enable manufacturing in our various factories

• Monitor availability taking holistic view of system health

• Measure and optimize system performance

• Provide operational support and engineering for several large-scale distributed software applications

• Design and implement automation for managing the deployment and upgrades of large-scale manufacturing software applications

• Define Disaster Recovery and Business Continuity plans for the various software deployments

• Improve observability of industrial automation software through metrics, logging, tracing, and alerting

• Design infrastructure, systems and application architecture

Chemical Engineering

• In this role, interns work directly with engineers and engineering technician on one of areas including mass and energy balance model development, new equipment at mini pilot/pilot scale design-built-commission, and engineering test planning and execution. Seeking candidates with experience with mass and energy balance using Excel and process modeling software like Aspen, SysCAD, HSC.

Crystallization Chemical Engineering

• This internship offers a unique opportunity to be involved in the early stages of a groundbreaking project. You will be supporting the crystallization team, working with engineering and operation departments to prepare for plant commissioning and start-up. Additionally, you will be interfacing with other refinery process areas to assist in making this refinery a success.

Cell Recycling Project Engineering

• As a Project Engineer, will interface with organizations across Tesla, Engineering, Production, Quality, Supply Chain, Production Planning, Operations, and the Executive team. You will work alongside existing Project engineers to assist with driving the development and deployment of new battery recycling processes.

Lithium Hydrometallurgy Engineering

• Tesla’s Lithium Hydrometallurgy Team is looking for engineering intern for a novel lithium hydroxide facility. You’ll be working alongside a muti-disciplinary team on the design of a first-of-a-kind plant to ensure readiness for both construction and operations. Seeking a candidate who has had exposure to hydrometallurgical, crystallization/solids separation processes and predictive solution chemistry.

Lab Materials Engineering

• This internship will focus on: materials development, process conceptualization and scale-up. These efforts are designed to improve the speed, efficiency, and environmental performance of battery material manufacture. The success of these initiatives is critical to unlocking a diversified, low-cost, sustainable energy ecosystem. You will join a team focused on recycling and primary metals refining.

Manufacturing Engineering

• This internship will focus on: project development and execution, process conceptualization and scale-up. These efforts are designed to improve the speed, efficiency, and environmental performance of battery material manufacture. You will assist in the day-to-day operation of multiple lab and pilot facilities. You will be a technical contact for one or more process steps and unit operations.

Production Engineering

• As a Production Engineer Intern at Tesla's Lithium Refinery, you will have the unique opportunity to contribute to the production process of lithium compounds used in the manufacturing of Tesla's electric vehicle batteries. This internship is designed to provide hands-on experience in a fast-paced, technology-driven environment, where you will work alongside a team of experts to optimize and enhance production processes while adhering to Tesla's commitment to sustainability and quality. Additionally, you will actively support commissioning and startup activities of the new refinery. Seeking candidates with basic knowledge of chemical engineering principles and unit operations. Familiarity with data analysis and statistical tools is advantageous.

Cathode Advanced Manufacturing

• Intern will participate in the development, measurement, and production of new cathode active materials and engineering / troubleshooting of the processes / measurements by which these powders are produced. This requires working in a hands-on capactiy with equipment and cathode materials.

Cathode Pilot Manufacturing Engeineering

• As a pilot line manufacturing intern, you will develop systems for operations, training, dashboard visualization of KPIs, inventory management and automation of manufacturing steps at pilot scale, and eventually be the first on-the-ground, technical point of contact for the understanding of how to scale and sustain cathode production quality at our first manufacturing plant in Austin. In this role you will also work closely with Tesla's teams around cathode manufacturing, material characterization, cell testing etc. to coordinate cross-functional activities that improve process control and product quality.

• Currently pursuing a degree in Chemical Engineering, Materials Science, or a related field
• Knowledge of chemistry, thermodynamics, engineering fundamentals, Li-ion batteries, cathode materials, or powder processing
• Proficiency in using engineering software and tools (e.g., MATLAB, AutoCAD, Plant 3D)
• Expereince in ASPEN, Power BI, Tableau, Python, R, TwinCat programming
• Experience in a R&D, powder production equipment, or materials development work

• Work as key link between cross functional teams to develop requirements and provide solutions for inline vision inspection systems
• Drive ramp of exciting new products by characterizing baseline vision performance and capability and improve performance as measured by product quality and tool availability
• Ensure manufacturing lines meet uptime, availability, and reliability metrics – OEE, cycle time and quality, and have the sense of urgency on resolution of production issues
• Develop best practices to improve vision system reliability
• Vision software and algorithm development and data analysis using programming languages such as C++, C#, Python or HALCON vision library
• Commissioning and calibrating vision systems and MES system integration
• Organize cross-functional design reviews and highlight body of work
• Collaboration with downstream and upstream process teams and quality team on vision system validation, data correlation, and analysis
• Build request for quotation and manage vendor proposals
• Provide direction and mentorship to third party vendors and Tesla Internal machine building teams

• Degree in Physics, Mechanical Engineering, Electrical Engineering, Computer Science or equivalent experience
• 5+ years of experience with machine vision systems
• Strong understanding of engineering fundamentals and ability to apply them towards manufacturing process development
• Knowledge in selection of cameras, lenses, optics, lighting, and other hardware for image capture and processing
• Knowledge of camera calibration (e.g., pinhole camera model, lens distortion, MTF of imaging system, gain and exposure setting, etc.)
• Strong analytical, mathematical, and statistical background and ability to understand and explain theory behind vision algorithms
• Experience of image processing (e.g., image enhancement, thresholding, morphology, feature extraction, etc.) is highly desired
• Experience with machine learning applications and image classification by deep learning is highly desired
• Experience in high volume manufacturing is highly desired
• Ability to travel

• Supervision of hourly maintenance and tooling technicians
• Manpower management: day to day line support; in-house equipment maintenance repair work; vacation scheduling; OT & weekend work scheduling
• Defining daily tasks and setting directions for the team
• Interaction with customer departments and Managers (Production, Engineering, General Assembly, Paint)
• Standard development and creation of procedure and methods
• Project management: both internal maintenance projects, and minor contractor projects
• Procedures & PMs, develop & maintain proper documentation of: all necessary procedures; periodic maintenance tasks; equipment changes (electrical, spare parts upgrades, mechanical), etc

• 5+ years of extensive experience with troubleshooting and correcting industrial equipment maintenance breakdowns and failures
• Hydraulic, mechanical, electrical, robotic and controls skills
• Injection Molding experience
• Project management experience
• Proficient in Microsoft Office suite of programs
• Proficient in using a CMMS database (FLUX)
• Must have the command of the English Language, both written and verbal

Physical Demands

• Ability to perform physically demanding work for extended periods of time, up to 12 hours a day
• Ability to stand and walk for up to 12 hours/day, including over varied and uneven terrain
• Frequently and repetitively, lift, push and carry up to 35 lbs., including the ability to carry 20 lbs. up and down stairs
• Frequently and repetitively, bend, lift and reach to install parts
• Stoop, lay, bend, reach, squat, kneel, crouch, twist and crawl for extended periods of time, including up to 12 hours/day
• Climb and maintain balance on ladders, scaffolding or other high structures
• Ability to find issues in a work process and receive safety signals using sight, touch, and hearing
• Wearing Personal Protective Equipment, including but not limited to: safety glasses, safety shoes, bump cap and adhering to prescribed safety rules and guidelines

• System Optimization: Lead the analysis, and optimization of mechanical systems, components, and equipment used in operational processes, ensuring alignment with performance, cost, and safety objectives
• Operational Support: Provide technical expertise to troubleshoot and resolve mechanical issues in real-time, minimizing downtime and enhancing operational reliability
• Project Leadership: Manage and execute engineering projects from inception to completion, including scoping, budgeting, scheduling, and coordination with cross-functional teams (e.g., manufacturing, quality, procurement)
• Process Improvement: Identify opportunities for continuous improvement in mechanical systems and operational workflows, implementing solutions to boost efficiency, reduce waste, and improve scalability
• Mentorship & Training: Guide and mentor junior engineers and technicians, fostering a culture of technical excellence and knowledge sharing within the operations team
• Compliance & Safety: Ensure all mechanical designs and operational practices comply with industry standards, regulations, and company safety protocols (e.g., ASME, ISO, OSHA)
• Documentation: Develop and maintain detailed technical documentation, including engineering drawings, specifications, maintenance procedures, and performance reports.
• Data-Driven Decision Making: Utilize data analysis and simulation tools (e.g., FEA, CFD) to predict system performance, validate designs, and inform operational strategies
• Supervise a team of engineers in charge of critical systems and utilities across Fremont and other sites

• Bachelor’s Degree in Mechanical Engineering or equivalent experience
• 15+ years of experience, with demonstrated leadership in operational engineering projects or teams
• Strong knowledge of mechanical systems, including HVAC, fluid dynamics, thermodynamics, and material science
• Experience with manufacturing processes (e.g., machining, welding, assembly) and equipment maintenance
• Soft Skills: Exceptional problem-solving and analytical abilities
• Strong communication skills, with the ability to present complex technical concepts to diverse audiences
• Proven leadership and project management experience, with a collaborative and proactive mindset
• Industry Knowledge: Experience in high-volume manufacturing or automotive production environments is highly desirable
• Hands-on experience with predictive maintenance technologies (e.g., vibration analysis, thermography); Knowledge of automation systems, robotics, or IoT integration in operational environments
• Ability to work in an operational environment, including occasional lifting (up to 50 lbs), standing for extended periods, and site visits to production or field locations as needed