Manufacturing Controls Engineer, LFP Cell Manufacturing

What You'll Do

• 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

What You'll Bring

• 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
• Strong root cause analysis and structured problem-solving skills (RCA, 8D, CAPA, PFMEA)
• Working knowledge of functional safety standards (IEC 61508/62061, ISO 13849) and safe design practices including LOTO and NFPA-70E
• 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

Benefits

• Competitive pay
• Medical plans
• Dental (including orthodontic coverage) and vision plans
• Healthcare and Dependent Care Flexible Spending Accounts (FSA)
• 401(k) with employer match, Employee Stock Purchase Plans, and other financial benefits
• Employee discounts and perks program
• Tesla Babies program
• Commuter benefits