Failure Analysis Engineer, Field Reliability, Cell Engineering

The Field Reliability team's mission is to determine root cause and contributing factors to improve the experience of Tesla’s products by reducing field issues, in collaboration with a large cross-section of other engineering teams. Engineers and Technicians on the team are responsible for a wide variety of battery and energy product systems for existing models and models in development. This role will focus on Failure Analysis activities of li-ion cells and the systems and sub-components they are used in, including teardown and inspection development, tool creation, and coordination with testing teams.  

We are seeking a multi-faceted individual who will be responsible for all aspects of identifying, analyzing, root causing, implementing countermeasures, and reporting on issues effecting our systems that rely on li-ion battery cells.

To be effective in this role, the engineer will need to be intimately familiar with the detailed behavior of batteries and their electro-chemical functions when used in our products, as well as the process of manufacturing battery cells. 

• Drive issue resolution from battery cell root cause analysis on field returned battery packs
• Investigate system assemblies, modules, components to identify root cause of failure in Tesla’s battery pack products
• Develop methods and execute teardown and failure analysis investigations on high voltage battery packs, modules, and related components  
• Document and communicate findings, techniques, and procedures 
• Present FA findings in broad team meetings  
• Coordinate and cross train other engineers and technicians 
• Continuous Improvement Initiatives: Lead incremental cell reliability with a practical, hands-on approach, utilizing reverse engineering, root cause analysis, and interpretation of various data sets
• Collaborate Across Teams: Work closely with vendors, in-house production, and engineering teams to proactively identify and troubleshoot issues, refine manufacturing processes, and implement solutions that enhance operational efficiency and reliability

• Bachelor's Degree in Mechanical Engineering, Materials Engineering, Reliability Engineering, or equivalent experience
• At least 3 years of relevant industry experience
• Excellent problem-solving, project management, and cross-functional collaboration skills
• Experience in laboratory setting using various tools (SEM/EDX, Cross Sectioning, XRF, ICP, Microscopy Analysis)
• Proficiency in data analytics tools (SQL, Power BI, Tableau preferred)
• Excellent written and verbal communication skills required