Failure Analysis Engineer Vehicle jobs at Tesla in United States, Lathrop

Specialize in Wireless technologies in manufacturing environments. This role will provide analytical, and technical guidance in build and operational support, wireless engineering and implementation support, and author knowledge articles. The engineer will ensure compliance to established system architecture, regulations and security policies. The engineer will play a key role in the implementation of design standards and best practices as outlined by the network architects.

• Work closely with Network Architects on supporting wireless design and initiatives
• Provide support, maintenance, and hands-on troubleshooting of our Lathrop factory/warehouses wireless network using available monitoring tools in the infrastructure
• Monitor, analyze, and report metrics of wireless solution
• Function as a Tier-2/3 escalation point
• Coordinate and lead on implementation of new wireless services
• Ensure wireless regulations and legal requirements are maintained
• Document enterprise wireless infrastructure components and “Run-Book”

• Extensive experience in wireless solution with IEEE 802.11 standards, encryption, WIDS, rogue detection, 802.1x, RADIUS, EAP-TLS, wireless client chipset/driver, RF engineering for wireless planning, along with multi-vendor technologies including Aruba Networks controller, AOS8, Aruba I/AP, Aruba ClearPass, Aruba Airwave, Mist wireless, Meraki wireless, and Splunk
• Working knowledge of TCP/IP layer protocols
• Extensive experience with various wireless tools such as Spectrum Analyzer, Protocol Analyzer, and Site Survey Tools such as Ekahau/Hamina
• Experience with wireless supporting voice and video application
• Proficient with Microsoft Word, Excel, PowerPoint, and Visio
• Solid analytical skills to troubleshoot high level, complex technical problems
• Excellent verbal, written, and communication
• Must be able to work occasional weekends, after hours, and holidays
• Ability to physically lift up to 50 pounds (22.7kg)
• Maintain a high degree of professionalism and integrity

• Drive issue resolution from root cause analysis to countermeasure implementation on electromechanical components from Tesla’s Energy Products
• Investigate system assemblies, modules, components to identify root cause of failure in Tesla’s Energy products
• Design and conduct fault replication tests experiments on power converters and low voltage PCBA's including board rework and FW/HW testing
• Collaborate with appropriate engineers, suppliers, and contract manufacturers to drive resolution to the identified failure causes
• Provide inputs to design and manufacturing teams to improve design and production yield
• Support design reviews and DFMEAs based on prior failure experience
• Candidate should be detail oriented with excellent communication skills

• Degree or relevant experience in Electrical/Electronics Engineering
• Strong demonstrable experience in Power Electronics/power converter circuits for energy storage/automotive applications
• Electrical/Electronic design experience a strong plus
• Strong demonstrable hands-on experience with electrical test equipment: Power Supplies, Multimeter, Oscilloscopes, and other common equipment
• Extremely proficient at reading schematics and troubleshooting analog and digital circuits
• Excellent written and verbal communication skills required
• Experience with hand tools, basic power tools, soldering, and instrumentation is desirable

• Overall responsibility for all controls related activities in the shop, leading and assisting production in all controls related topics and issues
• Provide guidance to maintenance team in troubleshooting difficult breakdowns and chronic equipment failures
• Develop & maintain proper documentation of all electrical equipment and associated procedures, making updates as required by modifications
• Create and improvements of equipment safety standards and the implementation of those standards into the manufacturing equipment, including periodic checks and qualification inspections

• 5+ years of professional controls engineering experience
• Proficient in CAD working with electrical diagrams and prints, proficiency with process integration and electromechanical / mechatronic systems
• In depth knowledge of electrical standards (NFPA79, National Electric code, UL508A) and safety standards (ANSI/RIA15.06, OSHA)
• Advanced proficiency programming industrial equipment, safety PLCs (Allen Bradley& Siemens preferably), Human Machine Interface (HMI / GUI – Allen Bradley, Siemens & Ignition), field bus Networks (ethernet IP, ProfiNet, safety rated field bus networks) and ethernet communications between machine PLCs and database systems
• Demonstrated excellence in programming PLCs. Must have a well-defined methodology for maintaining code structure and organization. Ability to program state machines for complex processes which involve multi-station parallel processing, pick and place automation, data acquisition, and PID control and proven ability to design fault-tolerant systems with error handling and recovery
• Exposure to a wide variety of production machinery, industrial sensors, and equipment (furnaces, high pressure die cast machines, trim presses, laser trim, plasma trim, CMT welding, DC nutrunner torque controllers, current and power meters, vision inspection systems, CNCs, etc.)
• Excellent robotic high level and background programming skills on Fanuc, KUKA, ABB or equivalent brands, hands-on experience commissioning and programming industrial robots, mechanical/electrical trouble shooting skills and experience with robot simulation packages as well as off-line programing using RoboGuide
• Proven leadership and project management experience transitioning products and processes from prototype to production desired, solid communication skills, both verbal and written. Ability to work well with others in a team environment as well as independently
• Great problem-solving skills and analytical thinking
• Flexibility in working weekends and night shift as required

• Lead controls commissioning efforts for more than seven different manufacturing lines
• Support and assist maintenance team in troubleshooting difficult breakdowns and chronic equipment failures related to control systems
• Responsible for implementing and managing continuous process optimization including the addition of advanced and conventional technologies to improve quality, productivity and reduce overall waste
• Overall responsibility for controls related activities in the production shop, leading and assisting production and maintenance in all controls related topics and issues
• Uses complex electrical schematics and blueprints to troubleshoot and correct problems
• Develop & maintain proper documentation of all electrical equipment and associated procedures, making updates as required by modifications
• Identify weak areas of the production systems using root cause analysis and first principles thinking and implement effective countermeasures using all available means
• Optimization and improvement of human machine interfaces, SCADA systems and MES interfaces
• Implement and enforce Tesla equipment safety standard into the manufacturing equipment, including periodic checks and qualification inspections
• Understand and program using several different programming styles, including ladder logic, structured text

• Degree in Electrical, Mechatronics, or Mechanical Engineering, or equivalent experience
• Ability to work night shift
• 4 + years of professional controls engineering experience
• 2+ years of advanced PLC programming knowledge on Rockwell, Siemens, Beckhoff or equivalent PLCs in a professional environment
• Experience with commissioning and troubleshooting servo and AC drive control systems
• Fanuc robotics programming skills desired
• HMI programming experience – Ignition and Wonderware
• Understanding of databases and various program languages (MySQL, Python)
• Proven project management experience
• Proficient in working with and creating electrical diagrams and prints

• Create and maintain PFMEAs to determine potential risks in manufacturing process and drive resolution of high-risk issues into process controls
• Establish and maintain Control Plans to assure critical features are controlled and monitored through the assembly/production processes as well as establish criteria for Part Inspection Standards based on product specification and process critical requirements
• Develop and implement Quality Key Points for visual inspection that meets product specifications used by in process inspections and quality audits
• Lead development and improvement efforts of the Quality Management System for the department as well as create schedule for regular audits and inspections to be performed by quality technicians across all product lines
• Review and provide disposition to non-conforming material and perform mechanical and electrical failure analysis on components and assemblies
• Lead and facilitate sorting activity and drive part improvement with suppliers on part non-conformances as well as lead containment activity on non-conforming material by determining appropriate suspect range to quarantine and provide disposition of material
• Track quality performance metrics from technician audits and organize regular reviews with all cross-functional stakeholders; prioritize top issues and drive continuous improvement activities as well as manage and develop team of quality technicians responsible for daily audits and quality improvements

• Degree in Mechanical, Electrical, Mechatronics, or Computer Engineering, or with equivalent experiences
• 7 years of experiences in quality or other disciplines in high volume manufacturing is preferred
• Experience managing a technical team, or other professional leadership experience as well as demonstrated ability to lead cross-functional initiatives and implement changes
• Experience conducting PFMEAs for production processes as well as experience in ISO-9001, QS-9000, ISO/TS/IATF 16949, APQP, PPAP is a plus
• Experience in 6-Sigma is a plus as well as specific training and demonstrated success in applying quality problem solving methods, such as fishbone diagrams and/or 8D, and implementing successful countermeasures
• Strong quantitative and data analysis skills, including process capability analysis, hypothesis testing, DoE, SPC, and similar
• Proficiency in SQL, R, Minitab (or similar) is a plus
• Experience with broad variety of measurement and inspection techniques as well as familiarity reliability test techniques (accelerated life testing) is a plus
• Excellent oral, written and presentation communication skills

• Create and maintain PFMEAs to determine potential risks in manufacturing process and drive resolution of high-risk issues into process controls
• Establish and maintain Control Plans to assure critical features are controlled and monitored through the assembly/production processes as well as establish criteria for Part Inspection Standards based on product specification and process critical requirements
• Develop and implement Quality Key Points for visual inspection that meets product specifications used by in process inspections and quality audits
• Lead development and improvement efforts of the Quality Management System for the department as well as create schedule for regular audits and inspections to be performed by quality technicians across all product lines
• Review and provide disposition to non-conforming material and perform mechanical and electrical failure analysis on components and assemblies
• Lead and facilitate sorting activity and drive part improvement with suppliers on part non-conformances as well as lead containment activity on non-conforming material by determining appropriate suspect range to quarantine and provide disposition of material
• Track quality performance metrics from technician audits and organize regular reviews with all cross-functional stakeholders; prioritize top issues and drive continuous improvement activities as well as manage and develop team of quality technicians responsible for daily audits and quality improvements

• Degree in Engineering (Mechanical, Electrical, Mechatronics, Computer Engineering, etc.) or other technical discipline or 3+ years’ work experience in manufacturing quality
• Experience managing a technical team, or other professional leadership experience as well as demonstrated ability to lead cross-functional initiatives and implement changes
• Experience conducting PFMEAs for production processes as well as experience in ISO-9001, QS-9000, ISO/TS/IATF 16949, APQP, PPAP is a plus
• Experience in 6-Sigma is a plus as well as specific training and demonstrated success in applying quality problem solving methods, such as fishbone diagrams and/or 8D, and implementing successful countermeasures
• Strong quantitative and data analysis skills, including process capability analysis, hypothesis testing, DoE, SPC, and similar
• Proficiency in SQL, R, Minitab (or similar), is a plus
• Experience with broad variety of measurement and inspection techniques as well as familiarity reliability test techniques (accelerated life testing) is a plus
• Excellent oral, written and presentation communication skills

• Identify, quantify, compare, and execute supply chain process improvements to drive cost reductions, capacity improvements, efficiency gains, and set operations up for success
• Create and implement tools to audit efficiency and identify cost reduction opportunities across Tesla
• Define and manage operational metrics for current and future production control systems
• Calculate, propose, and implement methods and processes for existing production control systems
• Define and maintain PFEP & work with Packaging engineering, supply chain and Quality to optimize
• Educate and engage cross-functional teams in importance of continuous improvement and supply chain best practice
• Manage and communicate improvement opportunities and implementation plans to all relevant levels and functions in the factory

• Degree in Engineering discipline, Engineering management, or equivalent experience
• 5 years of hands-on experiences in manufacturing environment is preferred
• Outstanding critical thinking and communication skills, with a very high level of emotional intelligence, autonomy, and servant leadership
• Innate ability to fully comprehend new processes and systems quickly, with high attention to detail
• Industrial cost control/reporting/analysis experience in high volume manufacturing environments
• Advanced-level MS Office skills (primarily Excel and Visio)
• Leadership/management experience and/or end-to-end project management experience
• Experience with industry-standard problem-solving methodologies (A3, ATS, UPS), preventive and autonomous maintenance concepts, time/motion study analysis, continuous improvement (6 sigma techniques, lean manufacturing), and change management
• Experience with applied mathematics and operations research (linear and non-linear programming, stochastic simulation methods)
• Experience with any/all of the following: simulation modeling software (FlexSim), data visualization software (Tableau), design software (SolidWorks, CATIA), programming languages (SQL, Python, MATLAB, VBA)