Process Engineer jobs in United States, New York, Buffalo

Lead the development and deployment of cutting-edge assembly and test processes for new manufacturing lines in Buffalo, NY. Driving high-quality and efficient production of power electronics for our cars and energy products. We're looking for a skilled manufacturing engineer who can design, develop, and implement innovative manufacturing processes that meet our high-volume production targets.

• Design and develop cutting-edge manufacturing processes that enable high-volume production of products with improved quality, reduced costs, and increased efficiency
• Deploy manufacturing processes and equipment to high-volume production, through rigorous tool qualification, process documentation, and training
• Ramp processes to meet high-volume production targets including cycle time, availability, yield, quality, and reliability, and driving a culture of continuous improvement
• Apply a range of manufacturing techniques, including fastening, welding, brazing, soldering, adhesive bonding, and other joining methods, and quality assurance methods such as vision inspection, leak testing, and electrical testing, to ensure products excellence
• Lead cross-functional teams to tackle complex problems, using rigorous problem-solving methods, data-driven decision making, and collaborative leadership to drive results

• 2-10 years of experience as a manufacturing engineer or similar, with direct responsibility for developing, deploying, ramping, and optimizing complex assembly processes in automated high-volume production environments
• Experience with lean and six sigma principles, including proficiency in tools such as DMAIC, Root Cause Analysis (RCA), Design of Experiments (DOE), Failure Mode and Effects Analysis (FMEA), Process Capability Analysis (PCA), statistical process control (SPC), and Kaizen
• Proficiency in data querying, analysis, and visualization using tools like MySQL, Python, R, JMP, or Tableau to make data-driven decisions and drive business results.
• Degree in Mechanical Engineering, Industrial Engineering, or a related field, or equivalent experience

• Responsible for the equipment performance and improvement of multiple assigned production processes
• Sustain 24 by 7 production operations through responding to and resolving breakdowns quickly and efficiently to minimize downtime
• Active participant of cross functional teams while taking on improvement projects to assist in improving the factoy and diagnose equipment failures, finds root cause and improve Overall Equipment Effectiveness
• Lead equipment upgrades with a focus on serviceability, reliability and process capability
• Develop and improve equipment validation procedures including calibration and qualification
• Become expert level trainer on all machines in assigned area and be responsible for the level of knowledge of Shift Technicians
• Provide hands-on support to Maintenance team to troubleshoot and resolve extended downtime situations
• Take initiative to create, implement and improve preventative and predictive Maintenance documents and schedules, under the direction of the Maintenance Planner
• Ability to troubleshoot ladder logic to appropriately identify controls issuesProgram ladder logic (Allen-Bradley, Siemens and Beckhoff). Ability to program and teach industrial 6-axis robots (Fanuc) Sequence complex, multi-station machinery for material pick-and-place, dispense, fastening, welding and conveyance applications
• Participate in spare part analysis and inventory development, cost reduction, mprovement working with Spares Department to RMA faulty components and communicate needs to the vendor

• Degree in Mechanical Engineering, Electrical Engineering, Industrial Engineering, Mechatronics, or equivalent experience
• 5+ years of engineering experience in a high volume environment
• Experience with 2D/ 3D modeling software (AUTOCAD and Solidworks/CATIA preferred)
• Vision system (Cognex and Keyence preferred) development & qualification experience
• Experience troubleshooting/teaching Fanuc Robotics
• Experience commissioning and improving Equipment. Have a demonstrated track record of Overall Equipment Effectiveness (OEE) improvement, Preventative and Predictive Maintenance activities
• Experience developing and improving HMI’s and with PLC (Allen Bradley preferred) programming, motion control, safety devices
• Experience coding/debugging and troubleshooting End of Line Test machines
• Good understanding of Computerized Maintenance Management System (CMMS), Safety, Ergonomics, Change Point Management, Spare Parts Management
• Strong problem solving skills and an aptitude for learning systems quickly. Able to utilize structured problem solving techniques such as DMAIC, Ishikawa, Five Why (5W) or Eight Disciplines (8D). Able to resolve high level performance issues into addressable actions

• Own/Lead Mechanical Design – 3D Part/Assembly Design, FEA Analysis & 2D Drawings with Dimensioning & Tolerancing (GD&T) in Solidworks
• Rapid Prototyping – Collaborate with cross functional engineers/teams, internal/external machine shops, internal 3D printing services, as well as third-party vendors to build, test, optimize and validate new parts, systems and/or full line equipment
• Collaborate with safety and ergonomic teams to review equipment/process requirements, compiling equipment risk assessments, and selecting/integrating safety devices into both new & existing manufacturing stations/lines
• Electrical & Controls Experience (Bonus) – Familiar with NACL electrical safety standards (NEC, CEN, etc.), communication/network protocols (TCP, IP, etc.), electrical hardware/wiring/schematic design (EPLAN, AutoCAD), and creating utility metrics for facilities systems (PDPs, compressed air, process water, etc.)
• Demonstrate strong project management skills – Collaborate with a wide variety of cross functional teams onsite (Product Design, Safety, Quality, Process, Production, Packaging, Facilities/Construction) to meet project stakeholder requirements
• Create New Line Make Cases or Existing Line Upgrade proposals by analyzing/creating equipment timing charts to optimize cycle times, balance automation based on calculated payback period (ROI), strategize PC material flow within factory, ensure adequate WIP buffering & production redundancies to ensure production uptime
• Experience with both Product & Manufacturing process failure mode analysis (PFMEA) as well as design failure mode analysis (DFMEA)
• External and Internal Vendor Management – Create RFQ’s in collaboration with procurement team to develop & identify cost effective solutions which are delivered on time.
• Own Root Cause Analysis – Preemptively/Reactively investigate, identify, and solve equipment & process concerns, production ramps, equipment reliability & yield for both new & existing equipment or methods
• Lead factory acceptance testing (FAT) with vendors at offsite locations as well as follow-up site acceptance testing (SAT) on equipment delivered & installed onsite

• Degree in Mechatronics Engineering, Robotics Engineering, Mechanical/Electrical Engineering, or equivalent experience
• 2-5 years’ experience with hands-on manufacturing engineering experience or related field/experience
• Proven proficiency with Solidworks for 3D Part/Assembly Design, 2D Drawings/Schematics, and Quotation + Procurement for Production Intent Parts/Equipment
• Rapid Design & Prototyping, 3D Printing, and first principles thinking to accelerate concept to production intent design
• Demonstrated strength of experience with both manual & automated high-volume manufacturing equipment
• Demonstrated experience initiating, evaluating, leading, and driving equipment design projects to completion
• Demonstrated experience with 8D, Six Sigma and Lean Fundamentals
• Proven leadership/ownership of large capital equipment projects & record of success.
• Evidence of exceptional ability & going beyond the call to action with excellent written and verbal communication skills required
• Display a positive attitude with flexible mindset as well as practice strong work ethic that reflects the mission, philosophy, and goals of Tesla

• Implement and optimize process control systems using working knowledge of chemical pretreatment parameters such as pH and conductivity. Minimize surface defects by improving surface preparation process
• Improve operations using working knowledge of powder coating principles, such as application mechanism of electrodeposition
• Develop and modify line layouts, including material flow, waste reduction, and ergonomics, utilizing Lean Manufacturing best practices
• Root Cause analysis of complex systems, and mitigation of failure modes via a systems approach
• Analyze and optimize production processes to ensure safety while maximizing Overall Equipment Effectiveness (OEE) in cost effective means while driving to achieve world-class quality levels
• Lead NCM (non-conforming material) activities, including the documentation and troubleshooting of line fall out
• Utilize structured problem-solving techniques such as DMAIC, Ishikawa, Five Why (5W) and Eight Disciplines (8D)
• Perform supporting activities for engineering and manufacturing including 5S and Lean manufacturing activities, material handling improvements, production line configuration, and safety procedures
• Monitor and reduce process variation using techniques such as Statistical Process Control (SPC) and Measurement Systems Analysis (MSA)
• Create and maintain Manufacturing Instructions, routings, and associated processes. Support 24 by 7 production operations

• Degree in Mechanical Engineering, Chemical Engineering, or equivalent experience
• 6+ years of experience developing and improving high volume processes. At least 2 years where automated methods are utilized in the finishing/coating of consumer products
• Experience with high-volume process equipment and automation including pre-treatment, e-coat equipment, paint/powder application equipment, paint/powder booths, ovens, conveyors & robotics
• Design for Manufacturability experience, Poka Yoke, and elimination of risk with design recommendations
• Background in automated systems (Electronics, Computer Controls, Electromechanical, Fastening, and/or IT Systems) is preferable to support End of Line (EOL) troubleshooting
• Have a demonstrated track record of Overall Equipment Effectiveness improvement activities
• Good understanding of Bill of Materials, Manufacturing Execution System, Specification Management, Change Point Management
• Linux, Tableau, SQL, Ignition, Minitab experience preferred
• Strong ability to work and communicate effectively with team and peers within a manufacturing and engineering organization. This includes excellent communication skills - written and verbal
• Creative capacity for developing new ways to do things better, cheaper, faster in alignment with the Tesla approach to revolutionary product development

• Maintain LabVIEW, Python, TestStand, and Golang production test software
• Generate user interfaces (GUI’s) as well as troubleshooting tools to improve the diagnostic capability of existing production test software
• Optimize automated processes to minimize cycle time and maximize uptime
• Validate using data-driven statistical approaches (such as Gage R&R, and Cpk)
• Design and industrial electrical control panels which are NFPA79/NEC/UL508A compliant, and create electrical, pneumatic and fluid schematics
• Develop test according to test procedures and specifications for both new make and Remanufactured components
• Provide on-site support for test equipment deployment
• Create troubleshooting and maintenance documents for testers
• Work with a team of Technicians to acquire new instruments and build fixtures to aid in verifying factory test equipment is operating correctly

• Degree in Electrical, Mechanical, or Software Engineering, or the equivalent relevant experience
• 4+ years of experience as a hands-on Manufacturing Test Software Engineer
• Experience commissioning test equipment, and root causing tester vs product issues
• Experience working with and debugging common communication protocols (CAN, Ethernet, GPIB, etc.)
• Experience with software version-control using one of the following tools: SVN, Git, or GitHub
• Exposure to data analytics using MySQL
• Familiarity with AutoCAD Electrical, EPLAN and SolidWorks
• Experience with high voltage environments is preferred but not required
• Understanding of three phase electrical systems, and power conversion electronics is a plus
• Willingness to travel domestically and internationally up to 10%

• Serve as a subject matter expert in MIG welding, resistance spot welding, and structural adhesive processes
• Perform Root Cause analysis of complex systems and mitigation of failure modes
• Lead production trials to optimize sub-systems and introduce new product designs
• Analyze production processes to ensure safety while maximizing Overall Equipment Effectiveness
• Lead non-conforming material (NCM) activities, including the documentation of rework procedures and troubleshooting of line fall out
• Utilize structured problem-solving techniques such as DMAIC, Ishikawa, Five Why (5W) and Eight Disciplines (8D). Perform supporting activities for manufacturing such as 5S and Lean initiatives, material handling improvements, and production line layout changes
• Monitor and reduce process variation using techniques such as Statistical Process Control (SPC) and Measurement Systems Analysis (MSA)
• Create and maintain manufacturing instructions, SCADA displays, operational dashboards, and associated processes
• Develop process sheets, PFMEAs, control plans, standard operating procedures, analyze and improve cycle time, balance workloads, and reduce bottlenecks
• Implement poke-yoke, process audits, root cause analysis for welding defects (e.g., porosity, undercuts)

• Degree in Mechanical Engineering, Mechatronics, Automotive Engineering, Structural Engineering, or equivalent experience
• Background in Geometric Dimensioning and Tolerancing (GD&T)
• 6+ years of experience developing and improving high volume manufacturing processes. At least 2 years of experience in spot welding, MIG welding, or other joining methods
• Ability to initiate design changes using the following principles: Design for Manufacturability, Poka Yoke, and elimination of failure modes
• Strong understanding of Bill of Materials, Manufacturing Execution System, Quality Specifications, Process Capability (Cpk), and Change Management
• Ability to utilize structured problem-solving techniques such as DMAIC, Ishikawa, Five Why (5W) or Eight Disciplines (8D)
• Excellent communication skills - written and verbal
• Ability to collaborate with cross-functional teams to solve highly technical problems
• Linux, Tableau, SQL, Ignition and/or Minitab experience preferred
• Fanuc robots and PLC programming experience preferred