About this role
The Field Reliability Engineering team's mission is to improve customer experience of Tesla products by reducing field issues, in collaboration with a large cross-section of other engineering teams.
This role owns the field reliability of the Low Voltage Distribution system across all Tesla vehicle programs: wire harnesses, connectors, terminals. Many of these failures have a mechanical failure mechanism but show up electrically as intermittent faults, lost communication or a vehicle that will not drive. We are looking for a hands-on mechatronic engineer who is comfortable with a cross-section, dimensional checks under the microscope and a wiring schematic, and who can take an issue from the first field signal through root cause to a fix on the line or in the design.
- Monitor field performance of LV harnesses, connectors and power distribution across all vehicle programs, and identify the top issues to improve
- Execute field investigations on harness and connector failures: intermittent opens, high resistance, shorts, water ingress, corrosion, chafe and thermal damage
- Data analysis on service, warranty and vehicle telemetry data to find trends by build date, factory, supplier and harness routing, and to prioritize investigations
- Perform vehicle and component level debug and failure analysis: continuity and voltage drop measurements, connector teardown, crimp cross-sections, terminal retention and pull tests, X-ray/CT and environmental reproduction
- Identify root-cause of problems using 1st principles and 5why methodology, separating design, supplier process, vehicle assembly and service-induced causes
- Coordinate and dispatch field failure investigations with harness suppliers, connector suppliers, vehicle manufacturing and the FA lab
- Drive containment and corrective action implementation: assembly process changes (connector seating, CPA engagement, routing and clipping), supplier process fixes, design changes and service procedures
- Feed field learnings back into harness and connector design (routing, packaging, sealing, terminal and connector selection) for current and future programs, including DFMEA input
- Communicate field performance of the LV distribution system, gather buy-in from engineering peers and leadership on improvement priorities and urgency
- Contribute to ongoing efforts for continuous improvement at Tesla, actively driving activities towards enhancing vehicle reliability, contributing to the continual optimization of Tesla's products and processes
- 0-5+ years of hands-on experience with wire harnesses, connectors or electro-mechanical systems in failure analysis, reliability, design or manufacturing, with a demonstrated problem-solving ability
- For out of school candidates, Co-ops or participation in student competitions such as Formula SAE, Baja SAE, Solar vehicle (especially harness or LV system ownership). A strong project that demonstrates problem solving skills is also accepted
- A mechanical or mechatronic background with solid electrical understanding: able to read wiring schematics and harness drawings, and to reason about current, voltage drop, contact resistance and heating
- Hands-on experience debugging and testing electrical systems in automotive or a comparable industry, using multimeter, micro-ohm meter, oscilloscope and microscope
- Understanding of connector and terminal failure mechanisms: fretting corrosion, crimp quality, terminal retention and backout, seal and water ingress, vibration, thermal cycling and material creep
- Familiarity with harness and connector standards (e.g. USCAR-2, USCAR-21, IPC/WHMA-A-620, LV 214) and with DFMEA/PFMEA is a plus
- Strong interpersonal and communication skills are an absolute requirement
- Strong attention to detail and analytical thinking
- Bachelor's or master's degree in mechatronic, mechanical, electrical or similar fields/equivalent experience required
- Previous experience in a manufacturing environment, harness supplier or vehicle assembly line, a plus
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)
Expected Compensation $91,600 - $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.