Tesla

The Optimus actuator team is seeking a skilled and highly motivated Gearbox Manufacturing Engineer to own assembly process development, equipment/automation, and test systems for precision gearbox component manufacturing and assembly at scale. You will develop robust assembly processes and lead the full lifecycle of manufacturing, assembly, and test equipment—from specification and design through sourcing, installation, commissioning, and production qualification—while driving OEE, yield, cycle time, and scrap performance for complex geartrains used in humanoid robot actuators. 

The ideal candidate thrives hands-on with assembly processes, production equipment, automation, and test systems; combines strong engineering fundamentals with practical line ownership; is highly organized with excellent attention to detail; and delivers continuous improvement under the pace of a high-growth robotics program. 

• Develop gearbox assembly processes: sequence, press fits, bearing preload, torque/angle, grease fill, sealing, and stack-up control
• Define assembly process parameters, work instructions, PFMEA, control plans, and error-proofing for cells and lines
• Qualify and stabilize assembly processes from prototype to production; drive capability (Cpk), first-article, and change control
• Specify, design/source, procure, install, commission, and qualify manufacturing, assembly, and test equipment/automation
• Develop and qualify in-process and EOL test systems (methods, fixtures, stands, scripts, data logging)
• Define test acceptance criteria, GR&R, and design correlation; own production release of test recipes
• Improve OEE, yield, and cycle time via process/equipment upgrades, line balancing, and continuous improvement
• Develop tooling/fixtures, and controls (PLCs, robotics, vision) for assembly and test of gearboxes
• Troubleshoot equipment, process, and test failures; develop spares strategy during line launch
• Support capacity/CapEx; create process and equipment docs; train teams; own KPIs and safety/line integration

• 3+ years developing and launching precision assembly processes (sequence, parameters, PFMEA, control plans)
• 3+ years specifying, procuring, installing, commissioning, and qualifying production equipment/automation
• Hands-on test development: in-process and EOL stands, methods, fixtures, data capture, and production release
• 3+ years in gearbox, actuator, or precision rotary product manufacturing and/or assembly
• Ability to read complex drawings and develop detailed CAD for fixtures/tooling that will go in to making gearbox assemblies 
• Degree in Mechanical Engineering or a related field preferred, or equivalent experience
• Background in gear/shaft/housing manufacturing processes (machining, finishing, grinding, heat-treat interface, metrology)
• Familiarity with test software/data systems (Matlab, LabVIEW, Python, PLC/HMI logging, MES/traceability) and GR&R/MSA preferred
• Experience with SPC, PFMEA, control plans, TPM/predictive maintenance, and lean manufacturing preferred
• Familiarity with PLC programming, robot teach/programming, or vision system setup preferred