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Sr Manufacturing Controls Dev Engineer

Company: Tesla Motors
Location: Sparks
Posted on: June 10, 2021

Job Description:

The Role

We are seeking a technically gifted Sr Manufacturing Controls Dev Engineer for the Gigafactory in Sparks Nevada to contribute to design and development of automation equipment for manufacturing test operations. The hired individual will work alongside several software, electrical and mechanical engineers to deliver and hand-off safe, robust world-class systems that will be used to test the technology on our cars. The perfect candidate will be expected to read and contribute to software architecture designs, understand (and occasionally design) electrical/pneumatic schematics and also show competence in basic mechanical concepts. Must also show competency in equipment safety.


Equipment development:

* Participate in initial equipment conceptual development and design reviews. * Lay out new industrial electrical control panels which are NFPA79/NEC/UL508A compliant, and create/assist with electrical, pneumatic and fluid schematics when needed. * 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), Python modules, golang modules, LabView, 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. * Review electrical cabinet builds, field wiring, pneumatic and fluid plumbing. * Select and size electrical and electromechanical components such as servos. * Identify manual processes that can be automated and deliver solid plan and concept to get this done. * Create machine interactions with plant-wide Manufacturing Execution System (MES) to communicate product acceptability, machine status, and process variables. * Enforce application of Tesla standards, work alongside project managers to supervise suppliers during specification, design review, design approval. * Establish test plans and control test plan execution at Vendor and at Tesla facility during installation and buy-off. * Characterize and validate new automated process equipment for deployment into production using a data driven approach such as simulation, Capacity and Capability statistical test (Gage Repeatability and Reproducibility test, Cpk, etc). * Debug and optimize automated processes to maximize cycle time, improve availability and yield. * 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/their hands-on work, analytical ability, organizational skills and attention to detail. They appreciate an environment where superior work is encouraged, noticed and rewarded and where individuals carry tremendous responsibility. They look forward to learning an incredible amount on the job.


* PLCs (Allen Bradley ControlLogix, Siemens TIA Portal, or Beckhoff TwinCAT) * Safety PLCs (Allen Bradley ControlLogix, SIMATIC Safety Integrated, or Beckhoff TwinSAFE) * Human Machine Interface (HMI / GUI - Ignition, Studio 5000 View Designer, SIMATIC WinCC (TIA Portal), or TwinCAT HMI) * Field bus Networks (Ethernet IP, PROFINET, EtherCAT) * Familiarity with Electrical prints and standard for Industrial equipment * Proficiency with process integration and electromechanical / mechatronic systems * Understanding of software concepts and architecture is a plus. * Competency in software programming in golang, python or c/c++/c# is a huge plus. * Familiarity with Cartesian, SCARA and Articulated robots is highly desired (Fanuc, Kuka, Motoman, Epson)

Preferred Experience:

* 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. * 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. * Project experience involving communications between PLCs and other software programming languages to safely control complex system is a huge plus. * Proficiency selecting appropriate circuit protectors, wire and cable, sensors, safety hardware, PLC hardware, remote I/O, VFD and servo systems. * 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, torque controllers, current and power meters, etc). * Experience programming Cartesian, SCARA and Articulated robots is highly desired (Fanuc, Kuka most preferred). * Experience with Vision systems (Cognex, Keyence, Fanuc). * Experience creating technical specifications for automated manufacturing equipment is highly desired. * Experience transitioning products and processes from prototype to production desired * Knowledge of production quality metrics is a plus. * Ability to use 3D CAD packages such as with SolidWorks and CATIA is a plus. * Industry or Project Experience in Automation.


* BS/MS Electrical Engineering (or equivalent - Majors in: Controls and Computer Control Systems, Mechatronic Engineering, Automation Engineering, Robotics, Software Engineering, Computer Science, etc.) * 1-4 years of experience as a hands-on Controls Engineer or Applications Engineer working on automation and/or electromechanical systems or 1 year of accumulated Internship experience in Controls or Automation.

Keywords: Tesla Motors, Sparks , Sr Manufacturing Controls Dev Engineer, Other , Sparks, Nevada

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