Robotics Manufacturing Engineer - Geartrain Manufacturing Equipment

Overview

The Optimus actuator team at Tesla is seeking a highly capable and motivated Gearbox Manufacturing Engineer. This role involves full ownership of equipment, automation, and system processes that enable high-precision manufacturing and assembly of gearbox components at scale. The engineer will manage the complete lifecycle of manufacturing and assembly equipment, from initial specification and design through installation, commissioning, and production qualification. The goal is to enhance overall equipment effectiveness (OEE), yield, cycle time, and minimize scrap for complex geartrains used in humanoid robot actuators.

Key Responsibilities

• Manage the specification, sourcing, procurement, installation, commissioning, and qualification of equipment and automation for gearbox component manufacturing and assembly lines, including CNC machining, finishing, heat treatment, metrology, servo/hydraulic presses, automation cells, robotic systems, and related process controls.
• Lead RFQ processes, supplier evaluation, factory acceptance testing, installation, integration, and commissioning of manufacturing and assembly equipment to ensure smooth connections with upstream and downstream processes.
• Drive continuous improvements to improve OEE by reducing downtime, changeover losses, and variation while increasing throughput and first-pass yield.
• Design and maintain preventive and predictive maintenance plans, tooling, fixtures, and controls such as PLCs, sensors, robotics, and machine vision to ensure consistent operational reliability.
• Troubleshoot failures, manage spare parts inventory and strategy, and lead root-cause analyses to eliminate recurring scrap and downtime.
• Support capacity planning and capital expenditure justification for new and upgraded production assets, including documentation creation and training for operators and engineers.
• Ensure compliance with safety and environmental health standards including machine guarding, lock-out/tag-out (LOTO), and safe handling of materials and press systems.
• Monitor and track process KPIs such as yield, cycle time, scrap, OEE, and uptime; report status and implement corrective actions.
• Develop and scale end-to-end manufacturing and assembly processes from prototype through high-volume production with detailed work instructions, process flows, and equipment validations.
• Collaborate on design for manufacturability (DFM) and assembly (DFA) activities and execute process validations including statistical capability studies, first-article inspections, and end-of-line testing.

Candidate Profile

• Minimum of 3 years experience specifying, procuring, installing, commissioning, and qualifying production equipment and automation for component manufacturing and assembly lines, including supplier management and production ramp-up.
• At least 3 years hands-on experience in gearbox, actuator, or precision rotary product manufacturing or process development.
• Strong knowledge of precision mechanical processes such as machining, finishing, press fits, bearing installation and preload, shaft stacking, and fastener selection.
• Proficient in reading and applying complex mechanical drawings including GD&T for components and assemblies like bearings, gears, shafts, housings, and actuators.
• Experience with 3D CAD tools (preferably CATIA/3DX or SolidWorks) for fixture and tooling design.
• Familiarity with manufacturing equipment and controls including CNC cells, servo/hydraulic presses, digital torque tools, fixtures, sensors, and industrial communication protocols.
• Degree in Mechanical Engineering or related field preferred; advanced degrees highly regarded or equivalent practical experience.
• Background in gear, shaft, and housing component manufacturing processes such as machining, finishing, grinding, heat treatment, and metrology is preferred.
• Knowledge of statistical process control (SPC), process failure modes and effects analysis (PFMEA), control plans, predictive maintenance, and lean manufacturing preferred.
• Familiarity with PLC programming, robot teaching/programming, vision systems, or manufacturing automation programming is advantageous.