Process Control Engineer, Cathode Manufacturing

Process Controls Engineers are responsible for maintaining, troubleshooting, and optimizing control systems across materials processing and manufacturing operations, ensuring the smooth operation of systems around the clock. This role involves close collaboration with cross-functional teams, including design, operations, and maintenance, to implement improvements, resolve system issues, and ensure compliance with industry standards and safety regulations. The position requires expertise in manufacturing controls, particularly for equipment used in material conveyance, milling, mixing, pressing, dryers, kilns, and robotic systems.
In addition to supporting day-to-day operations, Controls Engineers are responsible for establishing and maintaining equipment control standards, programming hardware and robots, and actively assisting with the commissioning and review processes for new projects. Additional duties include conducting audits, managing installations, and performing safety assessments to ensure all systems meet operational and regulatory requirements.

Responsibilities

• Program and debug control logic using structured text, ladder logic, and function block diagrams on PLC and DCS systems
• Develop code that adheres to established standards, ensuring it is organized, structured, documented, maintainable, and reusable
• Design and implement robust programs and control sequences for complex, multi-station machinery involved in processes such as material conveyance, milling, mixing, pressing, drying, kiln operations, and robotics
• Create intuitive Human Machine Interfaces (HMIs) using platforms such as Emerson DeltaV Live, Siemens WinCC, Beckhoff TCHMI, and others
• Set up, troubleshoot, and tune servo systems and Variable Frequency Drives (VFDs) for consistent and reliable operational performance (ABB, Siemens, Schneider, B&R, SEW)
• Design and implement reliable safety control systems to protect robots, gantries, conveyors, and other high-volume manufacturing equipment, ensuring compliance with relevant codes and standards
• Actively contribute to continuous improvement initiatives, including Root Cause Investigations (RCIs), by identifying and implementing corrective actions (e.g., optimizing control sequences, enhancing equipment interfaces)
• Oversee interface with Tesla's Manufacturing Execution System (MES) to troubleshoot and ensure seamless data integration into production databases

Requirements

• Bachelor's Degree in Electrical, Automation, or Chemical Engineering, Computer Science, or at least 5 years of experience in sustaining or designing control systems
• Proficiency with DCS systems, particularly Emerson DeltaV or Honeywell TDC/Experion
• Experience with PLC systems, with preference given to Siemens, Beckhoff, or B&R platforms
• Experience with Human Machine Interfaces (HMIs) and Graphical User Interfaces (GUIs), including DeltaV Live, WinCC, TCHMI, and Ignition
• Proficiency creating P&ID drawings and the ability to create and interpret detailed electrical and mechanical schematics using CAD tools (EPLAN preferred)
• Comfortable working in environments where Personal Protective Equipment (PPE) such as Powered Air Purifying Respirators (PAPR) may be required for safety compliance

Compensation and Benefits
Benefits

Along with competitive pay, as a full-time Tesla employee, you are eligible for the following benefits at day 1 of hire:

• Aetna PPO and HSA plans > 2 medical plan options with $0 payroll deduction
• Family-building, fertility, adoption and surrogacy benefits
• Dental (including orthodontic coverage) and vision plans, both have options with a $0 paycheck contribution
• Company Paid (Health Savings Account) HSA Contribution when enrolled in the High Deductible Aetna medical plan with HSA
• Healthcare and Dependent Care Flexible Spending Accounts (FSA)
• 401(k) with employer match, Employee Stock Purchase Plans, and other financial benefits
• Company paid Basic Life, AD&D, short-term and long-term disability insurance
• Employee Assistance Program
• Sick and Vacation time (Flex time for salary positions), and Paid Holidays
• Back-up childcare and parenting support resources
• Voluntary benefits to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance
• Weight Loss and Tobacco Cessation Programs
• Tesla Babies program
• Commuter benefits
• Employee discounts and perks program