(Associate) Process Engineer, Body - (m/w/d) - Gigafactory Berlin-Brandenburg

What To Expect

Tesla is looking for a self-motivated Process Engineer for the Bodyshop Model Y Engineering team at GFBB. This role requires a strong foundation in mechanical design, 3D simulation, and process validation, with a focus on enabling seamless production ramp-up and continuous improvement.

What You'll Do

• Contribute in the design, development, and validation of manufacturing fixtures (welding, assembly, handling, inspection) for new and existing body structures.
• Define and document end-to-end production processes from material input to final part output, including sequencing, cycle time, and workstation layout.
• Create and maintain 3D process layouts using CAD/CATIA, ensuring optimal space utilization, accessibility, and ergonomics for operators and automation.
• Collaborate with industrial designers, automation engineers, and maintenance teams to ensure fixtures are manufacturable, serviceable, and aligned with production needs.
• Drive process validation and verification through pilot builds, dimensional inspection, and data analysis to confirm conformance to engineering specifications.
• Develop standardized work instructions, control plans, and process flow diagrams to ensure consistency and traceability across production lines.
• Lead continuous improvement initiatives to reduce cycle time, improve part quality, and enhance fixture durability and ease of maintenance.
• Support new product introductions (NPI) by delivering fully validated fixture designs and process definitions ahead of production ramp-up.
• Maintain comprehensive technical documentation, including design records, change logs, and certification files for audit readiness.

What You'll Bring

• Bachelor's Degree in a Manufacturing Engineering related field, or equivalent experience
• Multiple years of experience in fixture design and process definition within high-volume automotive manufacturing environments. Proficient in 3D CAD software, particularly CATIA, with strong experience in modeling, assembly, and design for manufacturability (DFM).
• Experience with 3D simulation tools (e.g., Delmia, Siemens Tecnomatix, or similar) for process validation and robot path analysis is a plus.
• Demonstrated ability to translate engineering requirements into functional, reliable, and cost-effective fixture solutions.
• Strong understanding of tolerance analysis, GD&T, and dimensional control in complex assemblies.
• Experience working with automated systems (e.g., KUKA or FANUC robots) and integration with fixtures in production lines is a plus.
• Familiarity with Lean Manufacturing principles, Six Sigma, and structured problem-solving methodologies (e.g., 8D, 5 Whys).
• Excellent communication and collaboration skills across engineering, production, and maintenance teams.
• Proven track record of delivering complex fixture and process projects on time and within scope.

Candidates are expected to uphold and actively promote sustainability principles in their daily work, operating in line with Tesla Global Environmental, Health, Safety & Security (EHS&S) Policy and EMAS requirements, fostering a culture of continuous environmental improvement. Tesla