Manufacturing Controls Engineer, LFP Cell Manufacturing

Tesla is seeking a highly skilled and hands-on Controls Engineer to support the development, commissioning, and optimization of automation and control systems for LFP cell manufacturing operations. This role is a critical individual contributor position responsible for the day-to-day execution of controls engineering tasks that keep Tesla s next-generation battery cell production lines running at peak performance. You will work directly on the production floor, writing code, troubleshooting equipment, integrating systems, and driving improvements across safety, quality, rate, and cost.

• Develop program, and optimize PLC/PAC control systems (Siemens, Omron) and HMI/SCADA applications for automated battery cell manufacturing equipment including mixing, coating, winding, and assembly lines
• Design, implement, and troubleshoot motion/servo control systems, drives, and industrial networks (EtherNet/IP, PROFINET, EtherCAT) across production equipment
• Integrate machine vision systems, in-line metrology, and sensing instrumentation to support closed-loop process control, error-proofing (poka-yoke), and real-time traceability
• Implement and maintain functional safety systems including safety PLCs, safety-rate II/O, interlocks, and LOTO procedures in compliance with OSHA, NFPA-70E, IEC 61508/62061, and ISO 13849
• Support equipment commissioning, FAT/SAT acceptance testing, and production ramp activities for new automated lines and OEM-supplied equipment
• Respond to and resolve emergent controls issues including equipment faults, downtime events, and yield excursions; perform structured root cause analysis (RCA, 8D, CAPA) and implement permanent corrective actions
• Develop and maintain high-speed data acquisition, historian logging, and time-series data pipelines to support process monitoring, SPC, and OEE reporting
• Collaborate with Process, Production, and Manufacturing Engineering teams to ensure controls-validated transitions from equipment qualification to mass production
• Execute PFMEA, control plan development, and risk-based control design to proactively identify and mitigate process and equipment risks
• Maintain and improve preventive maintenance routines for controls-related hardware and software; participate in 24/7 sustaining operations coverage as needed
• Document controls architecture, wiring schematics, network diagrams, and software version control in accordance with Tesla engineering standards
• Support continuous improvement initiatives (Kaizen, DMAIC) targeting OEE, uptime, first-pass yield, and cycle time improvements
• Degree in Electrical, Controls, Mechatronics, or related Engineering discipline, or equivalent hands-on experience
• 3+ years of hands-on experience in controls engineering, automation, and manufacturing equipment in a high-volume, automated production environment
• Proficient in PLC/PAC programming (Allen-Bradley ControlLogix/CompactLogix, Siemens TIA Portal, or Beckhoff TwinCAT), HMI/SCADA development, and industrial networking protocols (EtherNet/IP, PROFINET, EtherCAT)
• Experience with servo/motion control platforms and drive commissioning (Kinetix, Sinamics, or equivalent)
• Hands-on experience with machine vision integration (Cognex, Keyence, or equivalent) and instrumentation/sensing for automated equipment
• Working knowledge of functional safety standards (IEC 61508/62061, ISO 13849) and safe design practices including LOTO and NFPA-70E
• Strong root cause analysis and structured problem-solving skills (RCA, 8D, CAPA, PFMEA)
• Ability to read and interpret electrical schematics, P&IDs, and mechanical drawings
• Familiarity with lithium-ion or LFP battery manufacturing processes (mixing, coating, winding, cell assembly) is a strong plus
• Adaptable to a compressed work week, night shifts, and a fast-paced, ever-changing manufacturing environment