Sr. Manufacturing Controls Dev Engineer, Automation & Controls, Castings

The Sr. Manufacturing Controls Development Engineer, Automation & Controls will own the PLC and HMI controls behind Tesla's new die casting lines, from controls concept and architecture through programming, FAT, installation, commissioning, and start of production. This is a controls-first role - Siemens TIA Portal PLC architecture, WinCC HMI, electrical design, and machine safety across the Giga Press lines, robotic cells, conveyors, and process monitoring systems - with hands-on exposure to robot integration and Ignition SCADA.

You will set the PLC and HMI standards every new line is built on, integrate robots, drives, vision, and SCADA into one coherent control system, and validate logic in simulation before equipment reaches the floor - driving down commissioning time and rework on every new line.

• Architect, develop, and debug Siemens PLC code in TIA Portal with an emphasis on code that is organized, structured, documented, maintainable, and reusable across equipment families
• Define and enforce Tesla PLC and HMI programming standards - program structure, UDTs, function block libraries, state machine sequencing, and alarm and fault handling - and validate logic in PLCSIM Advanced before equipment arrives
• Develop and optimize HMI applications in TIA Portal WinCC - generate aesthetically simple screens for complex machinery while providing sufficient feedback for troubleshooting
• Integrate and commission drives, motion, and field devices - SINAMICS VFDs and servo systems, remote I/O, sensors, and vision systems - over PROFINET and PROFIsafe
• Integrate FANUC robots with Siemens PLCs - handshaking, safe I/O, and error recovery over PROFINET/PROFIsafe or EtherNet/IP - partnering with robotics engineers to bring cells online
• Connect equipment to Ignition SCADA through OPC UA and consistent tag and UDT models, and build the supporting screens, alarming, and historian data for production visibility
• Implement control-reliable safety systems (ANSI/RIA R15.06, OSHA, ISO 13849) for robots, gantries, conveyors, presses, and other high-volume manufacturing equipment
• Read, interpret, and red-line industrial electrical schematics, lay out control panels that are NFPA 79 / NEC / UL 508A compliant, and produce electrical, pneumatic, and fluid schematics in EPLAN - specifying circuit protection, wire and cable, sensors, safety hardware, remote I/O, VFDs, and servo systems
• Participate in the development and enforcement of Tesla standards and manage suppliers through design reviews, FAT, installation, and start of production, traveling to supplier and installation sites as required
• Develop and maintain documentation, test methods, and commissioning procedures that reduce installation and ramp time

• Degree in Electrical, Mechatronics, or Controls Engineering, or equivalent experience
• 5+ years of professional controls engineering experience in high-volume automotive or heavy industrial manufacturing
• Advanced PLC programming on Siemens platforms (TIA Portal, S7-1500) in a professional environment, including safety controllers, plus HMI development in TIA Portal WinCC
• Strong structured programming skills - SCL and LAD/FBD, UDTs, reusable function block libraries, and state machine design - plus testing logic in PLCSIM or PLCSIM Advanced (Siemens SiCAR or another automotive controls standard preferred)
• Hands-on experience integrating and commissioning drives and motion - SINAMICS or comparable VFDs and servo systems - along with remote I/O and vision systems (Cognex, Keyence, Fanuc) over PROFINET and PROFIsafe
• Experience integrating industrial robots (FANUC preferred) with PLCs - handshaking, safe I/O, and error recovery - with the ability to read and make basic edits to robot programs
• Exposure to SCADA and plant data integration - Ignition 8 preferred (Perspective or Vision, tags and UDTs, alarming, historian) - plus OPC UA and working knowledge of SQL
• Proficiency reading and producing electrical schematics and control panel layouts in EPLAN (preferred) or CAD, including selection of circuit protectors, wire, cable, sensors, safety hardware, remote I/O, VFDs, and servo systems
• In-depth knowledge of electrical standards (NFPA 79, National Electric Code, UL 508A) and safety standards (ANSI/RIA R15.06, OSHA, ISO 13849)
• Strong collaboration and communication skills across mechanical, process, simulation, and maintenance teams, with a track record of delivering under aggressive timelines

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
• Earned Wage Access: Real-time pay access paid daily, subject to eligibility and schedule (applicable for below Sr. Managers levels)