Senior Manufacturing Controls Development Engineer - Automation & Robotics, Castings

Job Description

The Sr. Manufacturing Controls Development Engineer, Automation & Robotics will own the robotic automation behind Tesla's Die Casting operations, from robot cell concept through offline simulation, PLC integration, commissioning, and production ramp. This role pairs core Siemens controls ownership - TIA Portal PLC architecture, WinCC HMI, electrical design, and machine safety - with deep FANUC robotics capability across material handling, machine tending, and extraction cells serving the largest die cast machines in the world (Giga Press). You will define and enforce Tesla's robotic programming standards, build reusable program and error-recovery libraries, and validate cells offline in ROBOGUIDE before a robot is ever powered on the floor - driving down commissioning time and rework on every new line.

Job Responsibilities

• Lead the design, programming, and commissioning of robotic workcells using FANUC robots (R-30iB Plus / R-50iA controllers), optimizing reach, payload, kinematics, and cycle time
• Define and enforce Tesla-wide robotic standards for cell layout, tooling, I/O structure, safety integration, and error recovery, and maintain a reusable library of FANUC TP and KAREL programs and macros that accelerate future line builds
• Validate robot paths, cell layouts, and sequences offline in ROBOGUIDE (Process Simulate a plus) to de-risk integration and reduce on-site rework
• 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
• Integrate robots with Siemens PLCs across PROFINET/PROFIsafe, EtherNet/IP, and OPC UA, owning network architecture, handshaking, safe I/O, Dual Check Safety zones, and HMI synchronization
• Develop and optimize HMI applications in TIA Portal WinCC - generate aesthetically simple screens for complex machinery while providing sufficient feedback for troubleshooting
• 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

Job Requirements

• Degree in Electrical, Mechatronics, Controls, or Computer Engineering, or equivalent experience
• 5+ years of professional controls engineering experience in high-volume automotive or heavy industrial manufacturing
• 5+ years of advanced PLC programming on Siemens platforms (TIA Portal, S7-1500) in a professional environment, including safety controllers, plus HMI development in TIA Portal WinCC; Rockwell/Allen-Bradley experience a plus
• 5+ years of hands-on FANUC robotics experience (TP and KAREL programming, R-30iB Plus or newer controllers, mastering, payload setup, and frame calibration) including integration with Siemens PLCs over PROFINET/PROFIsafe or EtherNet/IP with safe motion and Dual Check Safety; ABB, KUKA, or Yaskawa experience a plus
• Demonstrated experience with robotic simulation and offline programming in ROBOGUIDE; Process Simulate, Tecnomatix, or Emulate3D a plus
• Deep understanding of robot kinematics, payload dynamics, singularity avoidance, and cycle time optimization
• Proficiency reading and producing electrical schematics (EPLAN preferred) and control panel layouts in 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), including robot cell safeguarding with light curtains, area scanners, interlocks, and speed-and-separation monitoring
• Experience with vision systems (Cognex, Keyence, FANUC)
• Strong collaboration and communication skills across mechanical, process, simulation, and maintenance teams, with a track record of delivering under aggressive timelines