Staff Manufacturing Controls Engineer, Castings

Tesla is seeking a highly motivated Controls Engineer to contribute to the design and development of new automation equipment and assembly lines.
The Controls Engineer will work to develop machine and process concepts along with several Manufacturing Engineering peers. Candidate will create a robust system architecture to support the concept. Will take care of everything, from building the electrical panel, to program all controls components such as PLC, safety devices, HMI, servo drives, process hardware and robots from power-on to debug, and finally to process fine tuning and validation. Once the equipment is in production, will also support all controls related topics and issues including troubleshooting and continuous improvement projects.
The Controls Engineer will also work with cross-functional teams throughout the entire life cycle of the product and processes. This role will work closely with Product Design Engineering, Quality, Process, Production and Maintenance to bring components from initial design, through prototype development and finally into full production.

Responsibilities

• Overall responsibility for all controls related activities in the shop, leading and assisting production in all controls related topics and issues
• Provide guidance to maintenance team in troubleshooting difficult breakdowns and chronic equipment failures
• Develop & maintain proper documentation of all electrical equipment and associated procedures, making updates as required by modifications
• Create and improvements of equipment safety standards and the implementation of those standards into the manufacturing equipment, including periodic checks and qualification inspections

Requirements

• 5+ years of professional controls engineering experience
• Proficient in CAD working with electrical diagrams and prints, proficiency with process integration and electromechanical / mechatronic systems
• In depth knowledge of electrical standards (NFPA79, National Electric code, UL508A) and safety standards (ANSI/RIA15.06, OSHA)
• Advanced proficiency programming industrial equipment, safety PLCs (Allen Bradley& Siemens preferably), Human Machine Interface (HMI / GUI - Allen Bradley, Siemens & Ignition), field bus Networks (ethernet IP, ProfiNet, safety rated field bus networks) and ethernet communications between machine PLCs and database systems
• Demonstrated excellence in programming PLCs. Must have a well-defined methodology for maintaining code structure and organization. Ability to program state machines for complex processes which involve multi-station parallel processing, pick and place automation, data acquisition, and PID control and proven ability to design fault-tolerant systems with error handling and recovery
• Exposure to a wide variety of production machinery, industrial sensors, and equipment (furnaces, high pressure die cast machines, trim presses, laser trim, plasma trim, CMT welding, DC nutrunner torque controllers, current and power meters, vision inspection systems, CNCs, etc.)
• Excellent robotic high level and background programming skills on Fanuc, KUKA, ABB or equivalent brands, hands-on experience commissioning and programming industrial robots, mechanical/electrical trouble shooting skills and experience with robot simulation packages as well as off-line programing using RoboGuide
• Proven leadership and project management experience transitioning products and processes from prototype to production desired, solid communication skills, both verbal and written. Ability to work well with others in a team environment as well as independently
• Great problem-solving skills and analytical thinking
• Flexibility in working weekends and night shift as required

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
Expected Compensation

$100,800 - $178,200/annual salary + cash and stock awards + benefits

Pay offered may vary depending on multiple individualized factors, including market location, job-related knowledge, skills, and experience. The total compensation package for this position may also include other elements dependent on the position offered. Details of participation in these benefit plans will be provided if an employee receives an offer of employment.