Manager, Structural Integrity


April 17, 2021

Manager, Structural Integrity
Location: Austin ,TX
The Role:
Structural Design Engineering group which designs body and battery structures is creating a Structural Integrity role to support Tesla’s growing adoption of large castings. With new factories coming online around the world, there is a need for processes to ensure that casting quality and consistency is maintained at each location.
The role will have the following areas of responsibility:
  • Global quality management systems for structural components

o Part requirements
§ Owner of Part Technical specifications (TS)
§ Assessment of issues & data collection for potential deviations to allow design engineers approval of deviations
§ Assessment and control of deviations and distribute to all programs/plants
§ Audit of implementation and execution (e.g. inspection standards, work instructions, rework methods, etc.)
o Failure analysis of new discontinuities/defects
§ Review load cases to determine appropriate test method, work with local quality to organize test, review results, provide feedback and document findings
§ Support design experiments to ensure statistical significance of failure modes
o Detection methods and frequencies
§ Standardizing control systems globally to detect and prevent non-conformances
§ Assessment of gages/tests methods (e.g. x-ray, component test)
§ Determination of testing frequency based on risk assessment
§ Audit of site control plans to ensure conformance between plants
o Risk/severity assessments
§ Owner of DFMEA
§ Participant in PFMEA

  • New Product Introduction

o Team to support for new production during RC, Pilot for every plant until SOP
o Sample selection, inspection, training, validation, test method verification, documentation, data collection, stratification and assessment
o Help hiring & upskilling local Quality team on methods, requirements, changes, etc.

  • Global structural quality KPI definition and tracking

o Work with each local quality team to create, maintain and track (yield, scrap, process capability, etc.)

  • Design and development for manufacturing/quality

o Lead structural design reviews & major changes
o Review of international regulatory requirements related to quality/design
o MRB review with each plant (issues, actions, processes, dispositions) and implementation of lessons learned globally
o Global continuous improvement projects (global cost savings, scrap reduction. design/process changes) and distribute best practices
o Participate in change review board for die design

  • Liaise between Plant Quality and Design Engineering
  • Advisory for SIE and structural casting suppliers
  • Recruit and manage engineers to support activities at various Tesla facilities


  • BS with 10+ years’ relevant experience

  • Evidence of exceptional ability.

  • 5 or more years of experience in a production environment and/or proven manufacturing development track record.

  • Position will offer unique and complex engineering challenges that require persistence, innovative thinking and a positive attitude

  • Must be able to work in a fast-paced environment, occasionally requiring extended hours

  • Proven ability to operate under pressure while managing multiple priorities simultaneously

  • Experience with semi-automated / automated manufacturing equipment a plus

  • Excellent communication skills, both verbal and written

  • Aptitude to learn and incorporate new technologies