Manufacturing Controls Engineer, General Assembly, Megafactory

Come make history with us. The Manufacturing Controls Engineer is responsible for sustaining, improving, and designing automated manufacturing equipment for the production line. They collaborate with test engineers and equipment engineers to maintain existing automated equipment, troubleshoot PLC-based equipment, and identify opportunities for process enhancement through new automation components. With strong controls engineering fundamentals, the ideal candidate is independent, proactive, hands-on, and detail-oriented.

Responsibilities

• Lead continuous improvement efforts using data-driven solutions to create a reliable and efficient manufacturing plant
• Support production ramp-up by troubleshooting mechanical automation equipment, Beckhoff PLCs, robots, motion controls, and vision systems. Address equipment issues, troubleshoot Beckhoff PLC and robot-related production problems, and develop maintenance documentation and training materials
• Develop and maintain Beckhoff PLC and HMI software to optimize operator and maintenance technician experience and ensure high-quality production
• Contribute to equipment conceptual development, considering product specifications, process control requirements, layout complexity, cost, quality, and lead time
• Create and approve electrical schematics, optimize equipment for safety and efficiency, and update HMI systems for complex machinery.
• Drive continuous improvement of automated equipment to enhance safety, quality, productivity, and cost metrics
• Conduct risk assessments and lead safety evaluations for equipment prior to launch
• Support 24/7 production operations as needed

Requirements

• Degree in Electrical, Mechanical, Mechatronics or Computer Science, or equivalent experience
• Minimum of 4+ years of hands-on experience as a mechanical/manufacturing controls engineer working with automation and electromechanical systems
• Advanced proficiency in programming industrial equipment using IEC 61131-3 languages, particularly structured text and ladder logic. Experience with PLCs (Siemens and Beckhoff a must and Allen Bradley preferred but not required) and Safety PLCs (Siemens, SIMATIC Integrated Safety or Beckhoff TwinSAFE)
• Proficiency in Human Machine Interface (HMI)/SCADA systems (SIMATIC WinCC (TIA Portal), TwinCAT HMI, or Ignition SCADA), and experience with Grafana
• Ability to select and integrate circuit protectors, sensors, safety hardware, PLC hardware, and other components
• Proficiency experience in programming robots (Fanuc articulated) and working with vision systems (Cognex, Keyence, IR Vision, etc.)
• Working experience with tools such as SEW EURODRIVE, Atlas Copco Fastening tools, Hipot Testers, CTS Leak Testers, Weld Controllers, etc. preferred
• Proven troubleshooting skills, root cause analysis, and problem-solving under tight timing constraints
• Knowledge of 3D CAD packages such as SolidWorks and CATIA is a plus
• Knowledge of Ethernet communications, script-based programming (Python, C++, GO), motor drives (SEW EURODRIVE or AB PowerFlex), and field bus networks is a plus

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

$86,400 - $151,200/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.