Sr. Manufacturing Controls Development Engineer, Machining

Description

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. We are seeking a Controls Development Engineer to lead the design, development, and deployment of Siemens-based controls systems for manufacturing equipment and automation. This includes controls architecture, SIMATIC PLC/HMI/safety software, industrial networking, equipment specification, and installation and commissioning. The candidate will work closely with internal cross-functional teams, external vendors, and technology partners on controls development from concept to production. This position requires 25% travel.

Responsibilities

• Lead cross-functional collaboration across process, equipment, mechanical, electrical, project management, and manufacturing stakeholders
• Document controls and equipment requirements, including I/O lists, network architecture, sequence of operations, safety requirements, and interface specifications
• Analyze controls architecture cost per unit and drive systems that maximize uptime, cycle time, and maintainability; lead design for controls/automation, reducing complexity and recoverability risk to lowest overall cost (equipment + integration + operating)
• Develop Siemens controls systems from concept to serial production, including SIMATIC S7 PLC and failsafe (F/H) safety PLC software in TIA Portal, WinCC HMI, SINAMICS motion, PROFINET networks, and integration with robots, CNCs, conveyance, and auxiliary equipment
• Perform detailed controls design based on process requirements, throughput, cycle time, and OEE, including fault handling, recovery sequences, and production data collection
• Define and optimize Siemens controls standards, TIA Portal project architecture, and reusable code libraries (FBs, FCs, UDTs, PLC data types) for cycle time, diagnostics, and maintainability across platforms
• Select, qualify, and manage Siemens controls hardware and software (S7-1500 / S7-1500F, ET 200SP I/O, WinCC, SINAMICS drives/servos, SCALANCE networking) and vendor-supplied equipment controls packages
• Lead controls qualification, including acceptance criteria, FAT/SAT, and verification of functional, safety, and performance requirements; develop and maintain schematics, network drawings, sequence of operations, safety risk assessments, and standard work
• Manage large-scale projects for new programs: timing plans and cost breakdowns for executive approval, risk identification and corrective action, status reporting, and oversight of installation and commissioning
• Drive continuous improvement of existing equipment controls to improve quality, reduce cycle time, increase uptime, and lower cost per unit

Requirements

• Degree in Electrical, Controls, Mechatronics, Computer, or Mechanical Engineering, or equivalent experience, with 5+ years developing and commissioning Siemens industrial controls in high-volume manufacturing, or equivalent experience
• Deep knowledge of Siemens SIMATIC PLC programming in TIA Portal (S7-1500 / S7-1200; STEP 7 Classic a plus), including SCL, LAD/FBD, state-based machine control, and structured, reusable program architecture
• Hands-on experience with Siemens WinCC (Comfort/Advanced/Unified) HMI, PROFINET design and diagnostics, and SINAMICS motion control (S120, G120, V90, or equivalent multi-axis servo/VFD applications)
• Experience with Siemens safety systems (S7-1500F / failsafe I/O, Safety Integrated, PROFIsafe, TIA Portal Safety) and strong understanding of ISO 13849, IEC 62061, IEC 61508, ANSI B11, and RIA R15.06, including risk assessment and safety function validation
• Experience developing, installing, and commissioning high-volume manufacturing equipment and automation (machining cells, robotic cells, conveyance, transfer systems, auxiliary equipment) on a Siemens controls platform
• Experience integrating Siemens controls with robots (Fanuc, KUKA, ABB, or equivalent), CNC/machine tools, vision systems, and higher-level systems (MES, WinCC SCADA / WinCC OA, historian); OPC UA and Siemens Openness/TIA scripting a plus
• Experience using Industrial Engineering methods in high-volume manufacturing; proficient in reading and developing electrical/controls schematics (EPLAN preferred; AutoCAD Electrical or equivalent); SolidWorks or similar a plus
• Proficient in PFMEA and controls FMEA development and deployment; new product introduction and manufacturing operations experience desired
• Mastery of MS Office suite, Confluence, Jira, software version control (Git, Siemens VCI, or equivalent) preferred; Allen-Bradley or other PLC platforms are a plus, not a substitute for Siemens depth
• 25% travel 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:

• 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