JAKE JAKUBOWSKI
San Jose,CA
Summary
Visionary, data-driven Operations and Engineering Executive (Ex-Tesla, Ex-Ford) with over 15 years of leadership in manufacturing, advanced production systems, and sustainable technology development. Proven record of transforming large-scale operations, scaling engineering organizations, and launching highly complex, next-generation technologies across automotive, industrial, machining, and ceramics environments. Expert in Lean Manufacturing, automation, quality systems, and digital operations, consistently delivering major gains in efficiency, cost, reliability, and throughput. Deep experience in full-cycle NPI, ECO governance, and complex change management. Recognized for driving organizational alignment, strengthening process capability, and accelerating the deployment of energy-efficient and sustainable manufacturing technologies. Seasoned Senior Director with significant experience in managing large teams and developing effective strategies. Strengths include strategic leadership, vision-driven change management, and robust business acumen. Achievements include driving operational efficiency and fostering cross-departmental collaboration within previous organizations.
Overview
17
17
years of professional experience
Work History
Senior Director - Operations & Engineering
Energy Recovery
San Leandro, CA
06.2025 - Current
- Achieved 17% reduction in labor costs and 40% increase in PPDLH through workflow redesign and labor optimization.
- Decreased scrap rate from 5% to 1.1%, resulting in over 20% annual scrap forecast reduction within five months.
- Streamlined S&OP process by implementing integrated planning software, enhancing inventory tracking and forecasting accuracy.
- Directed Engineering organization to govern ECO processes and ensure NPI readiness, minimizing obsolescence costs.
- Enhanced workforce reliability and throughput by utilizing TeamSense and badge-tracking systems with redesigned shifts.
- Championed capital investments for in-sourcing machining operations, cutting component costs without increasing overhead.
- Oversaw Maintenance Engineering & Facilities across two manufacturing plants with eight kilns and numerous CNC machines.
- Strengthened alignment among Supply Chain, Quality, and Engineering to accelerate changes and improve operational readiness.
- Implemented a comprehensive risk assessment framework that identified potential vulnerabilities, leading to a 30% reduction in operational disruptions.
- Facilitated stakeholder engagement sessions to align strategic objectives and ensure broad support for key initiatives.
- Optimized budget management processes, resulting in a 15% reduction in overhead costs while maintaining service quality.
- Established performance metrics that drove accountability and improved overall team efficiency by 20%.
Senior Manager - Manufacturing & Engineering
TESLA
Fremont, CA
10.2024 - 06.2025
- Led two major machine systems supporting high-volume aluminum casting for next-generation EV structural components.
- Increased system reliability and OEE through advanced diagnostics, predictive maintenance, and energy-efficient retrofits.
- Reduced energy and material waste by optimizing casting cooling cycles, material flow, and introducing automation best practices.
- Directed the introduction, validation, and release of new die designs, improving dimensional stability, reducing scrap, and strengthening long-term process capability.
- Accelerated die qualification timelines in partnership with Design, Tooling, and Quality organizations, ensuring seamless integration into high-volume production.
- Conducted comprehensive risk assessments to identify vulnerabilities, resulting in enhanced operational resilience and reduced downtime.
Senior Manager - General Assembly Operations & Engineering
TESLA
Fremont, CA
05.2023 - 10.2024
- Led day-to-day operations for a 2,500+ person organization during peak production scaling for Model 3 and Model Y.
- Delivered four consecutive labor-hour performance records, drove best-in-class efficiency, and supported a 6,000-unit production milestone.
- Launched the refreshed Model Y using a phased integration strategy that protected quality, prevented labor-cost increases, and maintained uninterrupted throughput.
- Reduced operating expenditures and optimized headcount while preserving production KPIs, quality performance, and ESG targets.
- Strengthened engineering coordination with Production, Quality, and Industrial Engineering to resolve constraints and maintain high daily output.
- Directed cross-functional teams to enhance product development cycles, reducing time-to-market by 15%.
Senior Manager - Quality Engineering, Model 3
TESLA
Fremont, CA
05.2021 - 05.2023
- Architected a plant-wide quality transformation integrating real-time analytics, structured problem-solving, and continuous improvement.
- Improved First Pass Yield and reduced rework/waste by more than 50%, significantly lowering energy and material consumption.
- Championed a culture of shared quality ownership, driving stronger cross-functional accountability and faster defect resolution.
- Enhanced Model 3 quality by over 50% through proactive issue management and tighter cross-department alignment.
Design & Release Engineer
Ford Motor Company
Dearborn, MI
01.2013 - 05.2021
- Led exterior body engineering focused on weight reduction, manufacturability, and sustainability.
- Executed launch of all-aluminum F150 and Expedition platforms-industry-first programs delivering significant fuel economy and emissions improvements.
- Developed design and manufacturing standards that improved supplier readiness and accelerated program delivery.
- Executed design release schedules, ensuring timely product launches and adherence to regulatory standards.
- Monitored supplier performance and quality metrics to maintain compliance with design specifications.
Integration Engineer (Ford Contract)
Ciber Inc.
Southfield, MI
01.2011 - 01.2013
- Built feasibility tracking systems and resolved multi-platform integration issues across Body and Chassis teams.
- Identified cost savings exceeding $1.2M in one year through strategic design and material choices.
Engineering Intern
Tedson Industries
Troy, MI
01.2009 - 01.2011
- Designed and prototyped energy-efficient automotive accessory components.
- Supported early-stage product development, testing, and manufacturing readiness.
Education
M.S. - Engineering Management
University of Michigan
Ann Arbor, MI01.2020
B.S. - Automotive Engineering & Design
Central Michigan University
Mount Pleasant, MI01.2012
A.S. - Automotive & Die Design
Macomb Community College
Warren, MI01.2010
Skills
- Executive operations leadership
- Energy efficiency and sustainability
- Advanced manufacturing and automation
- Product lifecycle management
- Engineering change management
- Program management
- Lean manufacturing and Six Sigma
- Capital project execution
- Strategic resource planning
- Quality systems management
- Continuous improvement strategies
- Organizational transformation
- Team leadership and development
- Supply chain management
- Budget management
- Human resources management
- Collaborative leadership
- Coaching and mentoring
Selected Highlights
- Led 37+ high-impact engineering projects at Tesla in 6 months, strengthening machine reliability and advancing sustainable manufacturing operations.
- Delivered a 17% reduction in PPDLH within 5 months by deploying cost- and time-optimization projects aligned with Lean and throughput priorities.
- Achieved 26% reduction in consumable spend while maintaining quality and safety standards.
- Improved Model 3 quality by >50% through proactive defect resolution and cross-functional accountability systems.
- Launched industry-first all-aluminum vehicle programs (Ford F150, Expedition), delivering major weight and fuel efficiency improvements.
- Managed full lifecycle development for energy-efficient manufacturing and casting solutions for next-generation EVs.
Timeline
Senior Director - Operations & Engineering
Energy Recovery
06.2025 - Current
Senior Manager - Manufacturing & Engineering
TESLA
10.2024 - 06.2025
Senior Manager - General Assembly Operations & Engineering
TESLA
05.2023 - 10.2024
Senior Manager - Quality Engineering, Model 3
TESLA
05.2021 - 05.2023
Design & Release Engineer
Ford Motor Company
01.2013 - 05.2021
Integration Engineer (Ford Contract)
Ciber Inc.
01.2011 - 01.2013
Engineering Intern
Tedson Industries
01.2009 - 01.2011
M.S. - Engineering Management
University of Michigan
B.S. - Automotive Engineering & Design
Central Michigan University
A.S. - Automotive & Die Design
Macomb Community College