Sr. Process Engineer, Castings, Cybercab (Night Shift)
Description
The Senior Process Engineer owns and controls the high-pressure die casting (HPDC) process for aluminum automotive giga-casting, including metal delivery, shot profile development, die thermal management, spray and extraction cycles, part removal, trimming, and secondary operations. This role sets and drives key manufacturing KPIs, optimizes existing processes, and partners cross-functionally to launch, qualify, and continuously improve casting processes, equipment, and work standards.
Responsibilities
- Set, track, and drive KPIs for Quality, Safety, Rate, Downtime, and process count
- Identify and implement process and line improvements to optimize factory performance
- Partner with Manufacturing, Design, MPI, and other teams to define, qualify, and document new processes
- Support Engineering and Manufacturing through 5S, Lean, material handling, line layout, and safety work
- Apply lean tools such as VSM, PFMEA, line balancing, and 5S for continuous improvement
- Own the full HPDC process, including metal delivery, shot profiles, thermal management, spray, extraction, trim, and secondary operations
- Analyze process and production data to improve capability, prevent defects, and stabilize casting quality
- Lead CI initiatives for quality, uptime, cost, and safety, working with Controls, Maintenance, Quality, Tooling, and Operations
- Support new tool launches with DFM input and initial casting trials
- Use Ignition, thermal system, die lube spray, VDU, and FANUC robot knowledge to monitor, set up, and troubleshoot process and equipment issues
Requirements
- Degree in Mechanical, Manufacturing, Metallurgical Engineering, or a related technical field, or equivalent experience
- 5–10 years of hands-on engineering experience in HPDC or foundry environments
- Strong knowledge of aluminum or magnesium metallurgy, heat treatment, machine capability, and secondary operations
- Proficiency with MAGMA, Flow-3D, or ProCAST casting simulation software
- Proficiency with NX, CATIA, or SolidWorks CAD
- Strong command of APQP, PPAP, FMEA, and DOE
- Desired experience with IDRA 6100 and 9000 ton machines for aluminum giga-casting
- Knowledge of VDU dosing systems for cycle time control and issue tracing
- Understanding of FANUC robots for spray and part extraction
- Full understanding of Ignition, thermal system software, and die lube micro-spray/electrostatic spray systems for setup, trending, and troubleshooting
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