Sr. Automation Controls Engineer, Gigafactory

Recruiter
Tesla
Location
Sparks, Nevada
Salary
Competitive
Posted
13 Oct 2018
Closes
19 Nov 2018
Ref
49141
Sector
Engineering
Contract Type
Permanent
Hours
Full Time
The Role

Tesla is seeking a highly motivated engineer for a Senior Controls position to focus on creating equipment for manufacturing and its sub-assemblies. This position concentrates specifically on controls of PLC driven robotic cells, servo actuated mechatronic systems and high volume automated process equipment. This is an exciting opportunity to build a world class manufacturing facility at the new Gigafactory in Sparks Nevada.

Responsibilities

Senior Controls Engineers work with cross-functional teams to design, validate, and finally roll-out equipment to full high volume production. Candidate will be key in driving standardization across all manufacturing lines and processes as well as with all other manufacturing product lines and Tesla factories.

He/She will work closely with external equipment integrators and internally with Product Design Engineering, Quality, Production and Maintenance to bring Tesla components from initial design, through prototype development and finally into full production.

Specific responsibilities include:
  • Develop company level, factory level and line/machine level controls standards and specification for application by internal equipment development team and external partners.
  • Create through to full deployment to production factory and line level controls architecture
  • Create data management and tracking communications network architecture and interface with cross-functional teams for product, processes and quality traceability control implementation
  • Create detailed utility layouts for entire assembly lines and interface with facilities teams for implementation
  • Lay out new industrial electrical control panels which are NFPA79/NEC/UL508A compliant, and create electrical, pneumatic and fluid schematics.
  • Participate in initial equipment conceptual development and carefully balance product specifications, process requirements, layout complexity, cost, and lead-time limits.
  • Lay out new industrial electrical control panels which are NFPA79/NEC/UL508A compliant, and create electrical, pneumatic and fluid schematics.
  • 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), LabView, machine vision, and 3 rd 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.
  • Manage electrical cabinet builds, field wiring, pneumatic and fluid plumbing.
  • Select and size electrical and electromechanical components such as servos.
  • Enforce application of Tesla standards, Manage external integrators 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 automated processes using a data driven statistical approach such as Capacity test, Capability test (Gage Repeatability and Reproducibility test, Cpk, etc)
  • Train Maintenance and Production teams to support automated equipment after deployment into production
  • Create machine interactions with plant-wide Manufacturing Execution System (MES) to communicate product acceptability, machine status, and process variables
  • Debug and optimize automated processes to maximize cycle time, improve availability and yield

The ideal Senior Controls Engineer candidate takes pride in his/her own work. Analytical ability, organizational skills and great attention to detail are of paramount importance. This candidate is familiar with and appreciates an environment where individuals carry tremendous responsibility and where superior work is encouraged, noticed, and rewarded. This candidate enjoys work, thrives on daily interaction with high-caliber people and has a keen understanding of how to work with and/or motivate them.

Requirements
  • BS/MS Electrical Engineering (or equivalent - Majors in: Controls and Computer Control Systems, Mechatronic Engineering, Automation Engineering, etc.)
  • 5+ years of experience as a hands-on Controls Engineer or Robotics Engineer working on automation and/or electromechanical systems.
  • 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:
    1. Ladder logic PLCs (Allen Bradley ControlLogix, CompactLogix and RSLogix 5000)
    2. Safety PLCs (Allen Bradley ControlLogix, SmartGuard, Omron, Pilz)
    3. Human Machine Interface (HMI / GUI - AB Panelview, FactoryTalk, LabView, Ignition)
    4. Field bus Networks (AB DeviceNet, Ethernet IP, Safety rated field bus networks)
    5. Serial communication (RS-232) between PLCs and instruments
    6. 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 selecting appropriate circuit protectors, wire and cable, sensors, safety hardware, PLC hardware, remote I/O, VFD and servo systems.
  • Proficiency creating detailed electrical and fluid schematics in CAD (AutoCAD Electrical preferred)
  • 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 highly desired (Fanuc, Kuka, Motoman, Epson)
  • 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

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