Sr. Process Engineer, Castings, Cybercab (Night Shift)
What to Expect 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.
What You'll Do 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
What You'll Bring 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
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
Earned Wage Access: Real-time pay access paid daily, subject to eligibility and schedule (applicable for below Sr. Managers levels)
Tesla is an Equal Opportunity / Affirmative Action employer committed to diversity in the workplace. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, age, national origin, disability, protected veteran status, gender identity or any other factor protected by applicable federal, state or local laws.
Tesla is also committed to working with and providing reasonable accommodations to individuals with disabilities. Please let your recruiter know if you need an accommodation at any point during the interview process.