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.
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. 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 life cycle of the product and processes. He/She will work closely with Product Design Engineering, Quality, Production and Maintenance to bring components from initial design, through prototype development and finally into full production.
What You'll Do
In-house equipment development:
• Participate in initial equipment conceptual development and carefully balance product specifications, process control requirements, layout complexity, cost, quality and lead-time limits.
• 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 Execution System (MES), machine vision, and 3rd 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 screens for complex machinery while providing sufficient feedback for troubleshooting.
• Introduce automated processes into production, and train and Maintenance and Production Teams to support after deployment into production
• Create machine interactions with plant-wide Manufacturing Execution System (MES) to communicate product acceptability, machine status, and process variables.
Existing automation equipment refinement:
• Debug and optimize automated processes to maximize cycle time, improve availability and yield.
• Characterize and validate automated processes using a data driven approach such as simulation, Capacity and Capability statistical test (Gage Repeatability and Reproducibility test, Cpk, etc)
• Assembly Line Development and Implementation
• Create data management and tracking communications network architecture and interface with cross-functional teams for product, processes and quality traceability control implementation
• The ideal candidate takes pride in his/her hands-on work, analytical ability, organizational skills and attention to detail. He/She appreciates an environment where superior work is encouraged, noticed and rewarded and where individuals carry tremendous responsibility. He/She looks forward to learning an incredible amount on the job.
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:
Safety PLCs (Allen Bradley& Siemens)
Human Machine Interface (HMI / GUI – Allen Bradley, Siemens & Ignition)
Field bus Networks (Ethernet IP, ProfiNet, Safety rated field bus networks)
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 programming and tuning 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 required (Fanuc, Kuka, Motoman, Epson)
Experience transitioning products and processes from prototype to production desired
Open to travel up to 25% of the year to Tesla sites, facilitating installations and handoff to cross-functional team members.
Nice to have:
Serial communication (RS-232) between PLCs and instruments (Nice to Have)
Experience with Vision systems (Cognex, Keyence, Fanuc) (Nice to have)
Knowledge of production quality metrics is a plus
Ability to use 3D CAD packages such as with SolidWorks and CATIA is a plus