Sr. Manufacturing Controls Dev Engineer, Coatings Process Equipment

Tesla s Manufacturing Engineering team is at the forefront of developing first-of-a-kind processes which allow us to produce amazing vehicles at best-in-class quality and rate in a safe and ergonomic environment. The Coatings team is seeking a Sr. Manufacturing Controls Development Engineer to own the electrical and controls architecture for technically complex process equipment used in pretreatment, electro-deposition (e-coat), application booths, air handling units, and industrial cure ovens. Working alongside the Manufacturing Process Equipment Engineer, you will lead all controls aspects of equipment development from concept through installation and production ramp - including panel design, PLC/HMI development, safety systems, vendor management, commissioning, and handoff to sustaining teams. The candidate will work closely with internal cross-functional teams, external vendors, and technology partners on controls development from concept to production. This role requires a thorough understanding of industrial automation and Manufacturing Engineering fundamentals. It is critical for a successful applicant to solve problems using first principles analysis and deliver organized, structured, documented, and reusable controls solutions. This position requires 25% travel.

• Participate in initial equipment conceptual development and carefully balance product specifications, process requirements, layout complexity, cost, and lead-time limits for coatings process equipment (pretreatment, e-coat, application booths, air handling, and industrial ovens)
• Lay out new industrial electrical control panels which are NFPA 79 / NEC / UL 508A compliant, and create electrical, pneumatic, and fluid schematics
• Architect, develop, and debug PLC code with an emphasis on generating code that is organized, structured, documented, maintainable, and reusable; PLC code will interact with subsystems such as conveyors, robots, tanks and recirculation systems, rectifiers, air handling units, ovens, Manufacturing Execution System (MES), machine vision, sensors/instrumentation, and 3rd party equipment
• Implement (ANSI/RIA R15.06 / OSHA compliant) control-reliable safety systems for safeguarding robots, gantries, conveyors, ovens, and other high-volume manufacturing equipment; integrate process safety interlocks appropriate to coatings equipment (oven safety, ventilation/airflow prove, fire suppression interfaces, e-coat grounding/isolation where applicable)
• Generate aesthetically simple HMI screens for complex machinery while providing clear feedback for troubleshooting and operator support
• Manage electrical cabinet builds, field wiring, pneumatic and fluid plumbing during build, installation, and commissioning
• Introduce automated processes into production, and train and equip sustaining teams to support automated equipment after deployment into production
• Install, commission, and start up equipment balancing speed and safety; support process qualification and buy-off with the Process Equipment Engineer using defined acceptance criteria
• Participate in Tesla specification and standard creation, release specifications to vendors and lead quote technical evaluation from a controls perspective, enforce application of Tesla standards, manage suppliers during specification, design review and approval for electrical/controls scope
• Characterize and validate new automated process equipment for deployment into production; support continuous improvement of existing coatings process equipment controls to improve quality, uptime, and maintainability
• Degree in Electrical, Controls, Mechatronics, or Manufacturing Engineering, or equivalent experience, with 5+ years of related experience developing and commissioning industrial automation and controls for high-volume manufacturing equipment, preferably in finishing/coating or similar continuous/flow process environments
• Exposure to programming at least two different types of PLCs and motor controllers - Siemens, Rockwell (Allen-Bradley), Beckhoff, and SEW are the primary equipment brands used in the factory
• Exposure to programming robots online and offline is a plus - Fanuc, Kuka, and Dürr are the primary brands used in the factory
• Demonstrate conceptual proficiency in the development of electrical and controls architectures for new equipment and lines, including industrial networks, safety PLCs, and integration with MES and 3rd party systems
• Experience implementing control-reliable safety systems per ANSI/RIA R15.06, OSHA, ISO 13849 / IEC 62061 (or equivalent), including risk assessment, guarding, and interlocks
• Proficiency with CAD for electrical/controls design (EPLAN, AutoCAD Electrical preferred; CATIA, SolidWorks a plus)
• Familiarity with coatings or wet-process equipment controls is a plus, including tanks/pumps/filtration, rectifiers, booth air handling, oven burners/heaters and temperature control, and related instrumentation (flow, level, pressure, temperature, conductivity/pH)
• Knowledge of NFPA 79, NEC, UL 508A for industrial control panels; familiarity with industrial oven safety standards (NFPA 86) and hazard area classification is a plus
• Proficient in PFMEA support, equipment qualification methods, and structured troubleshooting; new product introduction and manufacturing operations experience desired
• 25% travel required

Benefits

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

• Medical plans > 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 Accounts) HSA Contribution when enrolled in the High-Deductible 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 (90 day waiting period)
• Employee Assistance Program
• Sick and Vacation time (Flex time for salary positions, Accrued hours for Hourly 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

$109,600 - $234,000/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.