Sr. Manufacturing Engineer, Coatings Process Equipment

Description

Tesla’s Materials Manufacturing Engineering team is at the forefront of developing first-of-a-kind processes which allow us to produce amazing vehicles at best-in-class quality and rate in a safe and ergonomic environment.

The Coatings team is seeking a Sr Manufacturing Engineer for Application spray Booth & Air handling units Engineering and Design. You will design and develop technically complex booth & ait handling units design for coating applications, which includes process development, specification, validation, establishing and optimization of critical process parameters, design for manufacturing, equipment specification and design, as well as installation and commissioning. The candidate will work closely with internal cross-functional teams, external vendor & technology partners on process development from concept to production. This role requires a thorough understanding of Manufacturing Engineering fundamentals and substantial skills with 2D or 3D CAD software. It is critical for a successful applicant to solve problems using first principles analysis and exercise aggressive design optimization. This position requires up to 25% domestic and international travel.

Responsibilities

• Lead process equipment engineering from concept to production across pretreatment, electro-deposition, application booth, and industrial oven systems, including developing highly optimized equipment which simplifies the manufacturing process
• Lead research and development of pretreatment and electro-deposition equipment, including tanks, spray and immersion systems, piping, filtration, and rectifiers; conduct detailed analysis of chemical consumption, process heat requirements, application flow rates, electrocoat deposition rate, and corrosion and adhesion performance
• Lead design and development of application booth and air handling systems, including advanced air filtration and overspray capture/reclaim; conduct detailed analysis of air handling systems including psychrometric chart calculations, pressure drop calculations, and fan curves
• Lead design and development of industrial cure and bake ovens, including heating systems, recirculation and exhaust, temperature uniformity, dwell time, and energy efficiency; specify heaters, fans, ductwork, and safety interlocks
• Utilize computational fluid dynamics (CFD) software to simulate airflow patterns, fluid dynamics, drainage, spray coverage, throw power, coating thickness, and oven temperature/airflow uniformity to optimize equipment design
• Design and develop process equipment for manufacturing operations that comply with safety regulations and industry standards; review compliance with hazard area classifications, fire codes, mechanical codes, and applicable oven safety standards to maintain a safe working environment
• Specify and select filtration, ventilation, cyclone, piping, and heat-transfer systems to control particulate matter, maintain air quality, and maintain process quality
• Lead equipment and process qualification, including development of acceptance testing criteria and verifying process and equipment requirements using statistical tools (such as GR&R, SPC and Cp/Cpk)
• Lead equipment design for manufacturability (DFM), sustainability, and maintainability, including analysis of equipment design and identification of potential risks to the process, support FMEA, documentation of process requirements, develop solutions to address critical risks and steering process design to the lowest overall cost
• Design/Engineering/Management of large-scale projects for new programs, including the development of timing plans and cost breakdowns for executive approval, identification of risks to project timing driving corrective action, reporting of project status to executive team, and oversight of installation and commissioning of new manufacturing lines
  

Requirements

• Degree in Engineering (Manufacturing, Mechanical, Mechatronics or Chemical preferred) with minimum 5 years related experience in a technology-based industry, where automated methods are utilized in the finishing/coating of consumer products, or equivalent experience
• Experience working with or developing functional/aesthetic coating processes and associated process equipment, including pretreatment, electro-deposition, automotive paint and powder coating, application booths, and/or industrial ovens
• Experience in developing, executing, and interpreting results of Design of Experiments (DOE)
• Knowledge of hazard area classification, fire, and mechanical codes; familiarity with industrial oven safety standards (NFPA 86) is a plus
• Familiarity with filtration, ventilation, and cyclone systems for air quality and process quality control
• Proficient in calculating pressure drop, application flow rates, and designing piping and ductwork systems
• Proficient in using 2D/3D modeling software (Catia, SolidWorks, Inventor, ProE and/or AutoCAD)
• Familiar with using computational fluid dynamics (CFD) modeling software (Ansys and/or Autodesk CFD)
• Proficiency in designing mechanical equipment, fixtures and tooling in CAD, reading and interpreting mechanical drawings and electrical schematics, Automation industry standards, safety standards, development and deployment of PFMEAs
• Knowledge of MS Office suite, Confluence, Jira, Siemens, Allen Bradley PLC languages, HMI and SCADA is desired

Compensation and Benefits

Benefits

Along with competitive pay, as a full-time Tesla employee, you are eligible for the following benefits at day 1 of hire:

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

Expected Compensation

$109,600 - $195,600/annual salary + cash and stock awards + benefits

Pay offered may vary depending on multiple individualized factors, including market location, job-related knowledge, skills, and experience. The total compensation package for this position may also include other elements dependent on the position offered. Details of participation in these benefit plans will be provided if an employee receives an offer of employment.