Sr. Controls Engineer, Precision Machining, Optimus

Tesla is seeking a highly motivated Sr. Manufacturing Controls Engineer to join the Precision Machining, Optimus team in Lathrop, CA. The Sr. Manufacturing Controls Engineer is responsible for sustaining, improving, and integrating automated manufacturing equipment to the production line. They collaborate closely with equipment, quality, testing and process engineers to maintain existing automated equipment, troubleshoot PLC-based equipment, and identify opportunities for process enhancement through new automation components. With strong controls engineering fundamentals, the ideal candidate is independent, proactive, hands-on, and detail-oriented.

Responsibilities

Lead continuous improvement efforts using data-driven solutions to create a reliable and efficient manufacturing plant Support production ramp-up by troubleshooting mechanical automation equipment, PLCs, robots, motion controls, and vision systems Develop and maintain Beckhoff, Siemens, Allen-Bradley PLCs and HMIs software to optimize operator and maintenance technician experience and ensure high-quality production Contribute to equipment conceptual development, considering product specifications, process control requirements, layout complexity, cost, quality, and lead time Create electrical schematics, optimize equipment for safety and efficiency, and update HMI systems for complex machinery Address equipment issues, troubleshoot PLCs and robot-related production problems, and develop maintenance documentation and training materials Drive continuous improvement of automated equipment to enhance safety, quality, productivity, and cost metrics Participate in risk assessments and safety evaluations for equipment prior to launch Support 24/7 production operations as needed

Requirements

Degree in Electrical, Mechanical, Mechatronics or Computer Science, or equivalent experience Minimum of 4+ years of hands-on experience as a mechanical/manufacturing controls engineer working with automation and electromechanical systems Advanced proficiency in programming industrial equipment using IEC 61131-3 languages, particularly structured text and ladder logic Experience with PLCs (Siemens and Beckhoff a must. Allen Bradley is a plus but not required) and Safety PLCs (Siemens, SIMATIC Integrated Safety, TwinSAFE, PILZ) Proficiency in Human Machine Interface (HMI)/SCADA systems (SIMATIC WinCC (TIA Portal), TwinCAT HMI, or Ignition SCADA), and experience with Grafana Ability to select and integrate circuit protectors, sensors, safety hardware, PLC hardware, and other components Proficiency experience in programming robots (Fanuc 6+1 axis) and working with vision systems (Cognex, Keyence, IR Vision, etc.) Proven troubleshooting skills, root cause analysis, and problem-solving under tight timing constraints Knowledge of Ethernet communications (HTTP, MQTT, OPC), script-based programming (Python, C++, GO), motor drives (SEW EURODRIVE or AB PowerFlex), and field bus networks is a plus Preferred working experience with tools such as Atlas Copco Fastening tools, Hipot Testers, CTS Leak Testers, etc.