Staff Process Engineer, Powertrain

The Staff Process Engineer will serve as a senior technical leader focused on driving significant reductions in scrap, leading Corrective and Preventive Action (CAPA) initiatives, and developing robust, scalable manufacturing processes. Reporting to the quality group, this role combines deep process engineering expertise with data-driven problem solving to improve yield, reduce waste, and enhance overall manufacturing efficiency across high-volume production lines (Drive Unit, Battery, and related assemblies).

What You'll Do

• Lead scrap reduction initiatives targeting >20% improvement through root-cause analysis, process optimization, and implementation of sustainable countermeasures.

• Establish and maintain scrap tracking dashboards, Pareto analysis, and real-time monitoring systems to identify top loss drivers.

• Conduct detailed scrap teardowns, failure mode analysis, and data analytics to quantify losses and prioritize high-impact projects.

• Develop and execute scrap reduction roadmaps aligned with annual business objectives and quality targets.

• Own and drive timely closure of CAPA related to scrap, quality escapes, and process deviations.

• Facilitate structured problem-solving methodologies (5-Why, Fishbone, 8D, DMAIC) and ensure effective implementation of corrective and preventive measures.

• Validate CAPA effectiveness through follow-up audits, data review, and process capability studies (Cpk/Ppk, etc.).

• Lead process development and continuous improvement projects for new and existing manufacturing lines, with emphasis on automation, cycle time, and yield.

• Design, specify, and implement process changes, tooling, fixtures, and equipment modifications to reduce scrap and improve first-pass yield (FPY).

• Develop and maintain process documentation, work instructions, PFMEA, and control plans.

• Apply Lean, Six Sigma, and Genchi Genbutsu (“go and see”) principles to drive sustainable process improvements.

• Support new product introduction (NPI) by defining process parameters, conducting capability studies, and ensuring robust launch processes.

What You'll Bring

• Degree in Engineering, or equivalent experience

• 8+ years of process engineering experience in high-volume automotive or advanced manufacturing (body shop, battery, or drive unit assembly strongly preferred)

• Proven track record of delivering measurable scrap reduction (>15–20%) and yield improvement

• Strong experience leading CAPA / corrective action processes and structured problem solving

• Hands-on experience with process development, automation, robotics, and data analytics tools

• Excellent cross-functional leadership, communication, and mentoring skills

• Proficiency in statistical analysis, Minitab/JMP, and manufacturing execution systems (MES)

Benefits

• Competitive pay

• Medical plans > plan options with $0 payroll deduction

• 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

• Flexible Spending Accounts (FSA)

• 401(k) with employer match, Employee Stock Purchase Plans, and other financial benefits

• Employee Assistance Program

• Sick and Vacation time (Flex time for salary positions, Accrued hours for Hourly positions), and Paid Holidays

• Commuter benefits

• Tesla Babies program

• Employee discounts and perks program, Tesla