Controls Engineer, General Assembly Model 3

at  Tesla

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What to Expect
Tesla is seeking a highly motivated Controls Engineer to contribute to the design and development of new automation equipment and assembly lines for our advanced electric General Assembly. This is an exciting opportunity to build a world class manufacturing facility right here in the Bay Area. Tesla Motors is a demanding and fast-paced environment where you will work on a critical subsystem of incredibly exciting products.What You’ll Do
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, and then layout electrical/pneumatic schematics. Once the electrical panel is built, he/she will 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.
The Controls Engineer will also work with cross-functional teams throughout the entire lifecycle of the product and processes. He/She will work closely with Design Engineering, Quality and Production to bring Drivetrain components from initial design, through prototype development and finally into full production.

In-house equipment development:

• Participate in initial equipment conceptual development and carefully balance product specifications, process requirements, layout complexity, cost, and lead-time limits.
• Lay out new industrial electrical control panels which are NFPA79/NEC/UL508A compliant, and create electrical, pneumatic and fluid schematics.
• Architect, write, and debug PLC ladder logic with an emphasis on generating code that is organized, structured, documented, maintainable and reusable. PLC code will interact with subsystems such as conveyors, robots, Manufacturing System (MOS), machine vision, and 3 rd party equipment.
• Implement (ANSI/RIA15.06/OSHA compliant) control reliable safety systems for safeguarding robots, gantries, conveyors, and other high volume manufacturing equipment.
• Generate aesthetically simple HMI (Ignition based) screens for complex machinery while providing sufficient feedback for troubleshooting.
• Manage electrical cabinet builds, field wiring, pneumatic and fluid plumbing.
• Select and size electrical and electromechanical components such as servos.
• Introduce automated processes into production, and train and equip Sustaining Team to support automated equipment after deployment into production
• Create machine interactions with plant-wide Manufacturing System (MOS) to communicate product acceptability, machine status, and process variables.

Outsourced automation equipment development:

• Participate in specification creation, release to Vendor and quote technical evaluation
• Manage suppliers during specification, design, buyoff and installation of automated manufacturing equipment
• Establish test plans and control test plan execution
• Characterize and validate new automated equipment and fixturing for deployment into production

Existing automation equipment refinement:

• Debug and optimize automated processes to maximize cycle time and uptime.
• Characterize and validate automated processes using a data driven statistical approach such as Capacity test, Capability test (Gage Repeatability and Reproducibility test, Cpk, etc)

Assembly Line Development and Implementation

• Create detailed utility layouts for entire assembly lines and interface with facilities teams for implementation
• Create data management and tracking communications network architecture and interface with cross-functional teams for product, processes and quality traceability control implementation

What You’ll Bring

Proficiency with process integration and electromechanical / mechatronic systems

• In depth knowledge of Electrical Standards (NFPA79, National Electric code, UL508A).
• In depth knowledge of Safety standards (ANSI/RIA15.06, OSHA).
• Advanced proficiency programming industrial equipment:

1. Ladder logic PLCs on Allen Bradley ControlLogix (RSLogix 5000) and Siemens TIA Portal
2. Safety PLCs (Allen Bradley and Siemens)
3. Human Machine Interface (HMI / GUI - Ignition)
4. Field bus Networks (Ethernet IP, Profinet/Profisafe)

5. Serial communication (RS-232) between PLCs and instruments

6. 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. Proven ability to design fault-tolerant systems with error handling and recovery.
• Proficiency selecting appropriate circuit protectors, wire and cable, sensors, safety hardware, PLC hardware, remote I/O, VFD and servo systems.
• Proficiency creating detailed electrical and fluid schematics in CAD (AutoCAD Electrical preferred)
• Proficiency programming variable frequency drives
• Exposure to a wide variety of production machinery, industrial sensors, and equipment (LVDT and pressure transducers, dispense systems, temperature controllers, DC nutrunner torque controllers, current and power meters, etc)
• Experience programming Cartesian, SCARA and Articulated robots is highly desired (Fanuc, Kuka)
• Experience with Vision systems (Cognex, Keyence)
• Experience creating technical specifications for automated manufacturing equipment is highly desired
• Experience transitioning products and processes from prototype to production desired
• Knowledge of production quality metrics is a plus
• Proficiency with 3D CAD packages such as with SolidWorks and CATIA is a plus

QUALIFICATIONS

• BS/MS Electrical Engineering (or equivalent – Majors in: Controls and Computer Control Systems, Mechatronic Engineering, Automation Engineering, etc.). Equivalent experience also acceptable
• 3+ years of experience as a hands-on Controls Engineer or Applications Engineer working on automation and/or electromechanical systems.
  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)
• LGBTQ+ care concierge services
• 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
$80,000 - $258,000/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.
Tesla is an Equal Opportunity / Affirmative Action employer committed to diversity in the workplace. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, age, national origin, disability, protected veteran status, gender identity or any other factor protected by applicable federal, state or local laws.
Tesla is also committed to working with and providing reasonable accommodations to individuals with disabilities. Please let your recruiter know if you need an accommodation at any point during the interview process.

Please refer the Job description for details