Maintenance Engineer, Industrial Trucks Fleet (m/f/d) - Gigafactory Berlin-Brandenburg

What To Expect

Tesla is seeking a highly motivated and technically proficient Maintenance Engineer to join the dynamic team at our Gigafactory Berlin, responsible for ensuring the reliability, safety, and optimal performance of all industrial material handling equipment across the production floor. This role is critical to maintaining uninterrupted production flow, supporting high-volume manufacturing, and upholding Tesla’s commitment to innovation, efficiency, and operational excellence.

What You'll Do

Maintenance & Reliability Engineering

• Oversee preventive, predictive, and corrective maintenance strategies for all material handling equipment especially industrial truck fleet at GIGA Factory
• Implement condition monitoring techniques (vibration analysis, thermal imaging, oil analysis) to detect early signs of failure.
• Optimize maintenance schedules and work orders using FLUX (Computerized Maintenance Management System) to minimize downtime.
• Drive standardization of maintenance procedures across equipment types and teams.

Performance Optimization & OEE Improvement

• Monitor and analyze OEE (Overall Equipment Effectiveness) metrics for all material handling assets.
• Identify and eliminate losses (availability, performance, quality) through data-driven analysis and Kaizen events.
• Lead cross-functional OEE improvement projects with production, logistics, and engineering teams.
• Use real-time data (SCADA, MES, IoT sensors) to track equipment utilization and performance trends.

Problem Solving & Root Cause Analysis (RCA)

• Lead structured problem-solving for recurring equipment failures using methodologies such as 5 Whys, Fishbone (Ishikawa), and FMEA.
• Implement permanent corrective actions (PCAs) to prevent recurrence.
• Collaborate with suppliers and OEMs to resolve complex technical issues and improve equipment reliability.

Maintenance Cost Reduction & Sustainability

• Conduct cost‑benefit analyses for maintenance activities, spare parts, and repair vs. replace decisions.
• Optimize spare parts inventory using ABC analysis and demand forecasting to reduce carrying costs.
• Identify opportunities for energy efficiency improvements (e.g., battery management, regenerative breaking, idle power reduction).
• Support circular economic initiatives (e.g., refurbishment, recycling of components).

Team Collaboration & Continuous Improvement

• Mentor and train maintenance technicians and operators on best practices, safety, and equipment care.
• Partner with Production, Logistics, and Engineering teams to align maintenance strategy with production goals.
• Contribute to Lean Manufacturing, Six Sigma, and continuous improvement (CI) initiatives.
• Prepare and present performance reports and improvement plans to leadership teams.
• Support reporting manager in day‑to‑day maintenance related activities, KPIs reports, budget tracking, etc.

What You'll Bring

• Bachelor's degree in mechanical engineering, Mechatronics Engineering, Industrial Engineering, or a related technical field (minimum requirement).
• 5+ years of experience in equipment engineering, maintenance engineering, or reliability engineering in a high-volume manufacturing environment (ideally automotive background).
• Knowledge of manufacturing processes, logistics operations, manufacturing equipments like electric forklifts, reach trucks, tuggers, AGVs, and automated material handling systems.
• Good understanding of electrical, mechanical, hydraulic and control systems, including PLCs, HMI, and sensor integration.
• Hands‑on experience with CMMS (e.g., SAP PM, Maximo, IBM Maximo), SCADA/MES systems, and data analytics tools (Excel, Power BI, Tableau).
• Demonstrated ability to analyze OEE data, identify bottlenecks, and implement measurable improvements.
• Proficiency in root cause analysis (RCA) and problem-solving methodologies (8D, DMAIC).
• Experience with maintenance cost modeling, spare parts optimization, and lifecycle cost analysis.
• Strong project management and stakeholder communication skills.
• Ability to work independently, manage multiple priorities, and deliver results in a fast‑paced environment.
• Willingness to work flexible shifts, including weekends and overtime, as required by production needs.