Sr. Manufacturing Engineer, Metal Forming

Overview

Tesla is seeking a highly experienced Sr. Manufacturing Engineer, Metal Forming to join our vehicle manufacturing engineering team at Gigafactory Texas. In this senior role, you will lead the design and optimization of metal forming equipment and processes for high-volume production of vehicle components for models like Model Y, Cybertruck, and future programs. You will drive efficiency, quality, and innovation in press and automation design, installation, commissioning, and collaborate with cross-functional teams to ensure seamless integration of our automated manufacturing lines.

This position requires deep expertise in metal forming, simulation tools, and process improvements to support Tesla's mission of accelerating the world's transition to sustainable energy.

• Design, implement, and improve stamping presses and automation processes for highest safety, quality, and efficiency while reducing overall cost to enable vehicle production at rate
• Collaborate with product & die engineering teams on DFM of various components to allow for an efficient manufacturing process
• Commission production processes and equipment using factory and site acceptance testing
• Define a robust process control plan to enable high level of quality
• Support make vs. buy, and ROI analyses as required, while validating external components suppliers using industry standard PPAP methodology
• Collaborate with external vendors and internal stakeholders to conduct design reviews of the production equipment throughout the development process
• Plan sufficient capacity to meet business targets for production output
• Assess and reduce risk in the assembly process using PFMEA methodology

• Degree in Mechanical Engineering, Mechatronics Engineering, Industrial Engineering, Electrical Engineering or equivalent experience
• 4+ years of experience in manufacturing engineering, with a focus on stamping equipment in high-volume environments (e.g. automotive or aerospace)
• 4+ years of experience in stamping press operations, including equipment design, hydraulic/servo systems, and material handling for metals like aluminum and steel
• 4+ years of experience with engineering tools and software, such as CAD (e.g., Solid Works, AutoCAD), simulation software (e.g., Auto Form, Siemens NX), and PLC programming (e.g., Allen-Bradley, Siemens)
• 4+ years of experience in leading root-cause analysis, process optimization, and equipment upgrades using methodologies like Six Sigma, Lean Manufacturing, or Kaizen
• 4+ years of experience with industrial automation, including robotics (e.g., Fanuc, KUKA), vision systems, and communication protocols (e.g., Ether
  
  CAT, Profinet);
  Excellent problem-solving skills with a track record of resolving equipment issues in 24/7 production settings
• Requires domestic travel up to 5% and international travel up to 5% to support design reviews, equipment acceptance testing and global equipment installation efforts
• Employer will accept any suitable combination of education, training, or experience

Benefits

• Medical plans with plan options and $0 payroll deduction
• Family-building, fertility, adoption and surrogacy benefits
• Dental (including orthodontic coverage) and vision plans, both with options with a $0 paycheck contribution
• Company Paid Health Savings Account (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 salaried 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