Process Engineer High Pressure Die Casting /Prozessingenieur Druckguss - Gigafactory Berlin-Brandenburg in Grünheide (Mark) bei Tesla

You will be an integral part of global Materials Engineering organization, pursuing our mission to provide Materials, Processes, and work together with Tesla’s Engineers and Manufacturing Facilities teams with a competitive advantage in their mission to design and produce products that accelerate the world to sustainable energy. You will work closely with our engineering teams in the early and stabilization phases of high pressure die casting process development and equipment commissioning to infuse PFMEA/DFMEA thinking and identify manufacturing risks associated with our proposed designs and procedures always aiming to improve and stabilize main KPIs, cycle time, yield, OEE and Cycle time.

• Lead new high pressure die casting products launching by knowing main critical or concerning issues related to tooling, machine, and operator side.
• Install process parameters and controls to standardize and hand it over into production as well as process control systems.
• To drive main activities to have quick and accurate impact on Yield rate, customer claims, cycle time and OEE.
• Developing process improvements that can have impact globally in other tesla factories
• Lead process development of the die cast process through parameter optimization, DOE experiments, and trials that will lead to a robust process.
• Lead and refine the DFM process (Manufacturing, Assembly, Supply Chain, Cost, Serviceability, Sustainability, Reliability, Safety, etc.) and work closely with product design engineering teams to ensure that critical changes are incorporated in a timely manner.
• Oversee operator instructions, critical parameters, checklists, and training materials for all casting operations, update special equipment service manuals including BOMs, drawings, wiring schematics, recommended needed processes, technical expertise, and tooling for optimization of production runs.
• Research, design process & implement automation technology and integration approaches to support Tesla’s in-house aluminum die casting foundry facility.
• Install, assemble, and test presses, fixtures, gaging, robotic grippers & special machines while driving process improvements, cost reduction activities and continuous improvement activities.

• Degree in Mechanical, Materials Engineering or related field, or equivalent experience.
• Exceptional understanding of the interactions between the high pressure die casting process conditions (e.g. die temperature, die & tip lube application, shot profile, etc.) influence the metallurgical and structural integrity of cast aluminum components.
• 3+ years of experience in high pressure aluminum die casting process design, manufacturing engineering, equipment commissioning, robot programming and control systems design.
• Experience developing manufacturing processes for new and unique products.
• Demonstrated examples of obsessive emphasis on process control.
• Experience transitioning products from prototype to production.
• Experience defining and assessing quality standards associated with common manufacturing processes including drawing specifications, limit samples, and incoming/outgoing quality control points with a proven track-record of shepherding products from tool release to mass production
• Experience with manufacturing process like injection molding, CNC, die casting, stamping, assembly, and box build in a production setting and a good understanding of the costs and schedule and complexity associated with each process.