Controls Development Engineer, Automation & Data Systems, Fremont Central Manufacturing Engineering

Manufacturing Controls Development Engineer, Automation & Data SystemsThe Manufacturing Controls Development Engineer, Automation & Data Systems position is located at our Fremont Factory location. The primary responsibility of this role is to apply first principles thinking to design, develop, and maintain core controls systems that bridge manufacturing gaps. This involves innovating automation and data architectures grounded in electrical design fundamentals, software development principles, data systems architecture, control system theory, and cybersecurity to mitigate threats—tackling complex, real-world challenges in a fast-paced environment that demands creative problem-solving and continuous learning.

It includes integrating PLC/SCADA with advanced manufacturing and energy systems for physics-driven optimization of production processes, plus creating scalable systems for functionality enhancements, quality inspection, real-time process optimization, and predictive maintenance through condition monitoring and equipment reliability analysis.ResponsibilitiesHelp design automation and data architectures grounded in electrical design, engineering fundamentals, software development principles, data systems architecture, and control theory, with a focus on integrating condition monitoring for motors, pumps, and other critical equipmentCreate scalable systems for production output, quality inspection, real-time process optimization, and predictive maintenance strategies to enhance equipment uptime and reliabilityDesign and develop manufacturing data systems from concept to production, analyzing equipment KPI trends, conducting reliability analysis, and implementing predictive models to forecast failures in motors, pumps, and related systemsImplement cloud-based solutions for data collection/storage, using Python/SQL to interface with MES and production databases, while incorporating sensor data for real-time condition monitoring and fault predictionDesign, program, and commission automation equipment to improve systems, including predictive maintenance tools that leverage historical data for proactive interventionsPredict faults from machine data (e.g., vibration, temperature, and performance metrics for motors and pumps), coordinate cross-functional alerts/corrective actions based on reliability analysis, and maintain CI/CD pipelines for tracking and reporting predictive maintenance outcomesOptimize HMI/SCADA/MES interfaces; conduct in-house tech exploration, implement safety standards with periodic inspections, and integrate predictive analytics for equipment health monitoringContribute to OT cybersecurity projects to secure manufacturing networks and devices against threats, ensuring robust protection for data streams from condition monitoring systemsRequirementsDegree in Computer Science, Computer Engineering, Electrical Engineering, Mechanical Engineering, or equivalent relevant industry experience2-5 years of hands-on experience as a Controls Engineer or Applications Engineer, working on automation/electromechanical systems in industrial, high-tech/R&D, biotech/pharma, food/beverage, or advanced manufacturing (e.g., battery production) environments; recent graduates or entry-level candidates with relevant internships or projects encouraged to applyProficiency in industrial systems including configuring control networks (Ethernet/IP, PROFINET, BACnet, Serial Communication), PLC programming (Siemens, Allen-Bradley, Beckhoff, etc.), designing and implementing safety systems, and developing HMIs (at least one of the following: Ignition, WinCC)Deep understanding of first principles in electrical design (including electrical schematic design using ePLAN for circuits and power distribution), software development, data systems architecture, and control theory, with specialized knowledge in condition monitoring techniques for motors and pumpsHands-on experience in manufacturing settings, solving complex problems via foundational breakdowns in software, data, and electrical design, including proven results in predictive maintenance programs that have improved equipment reliability and reduced downtimeProficiency in Python and SQL, with experience applying these to analyze sensor data for equipment reliability analysis and predictive modelingHands-on experience troubleshooting and fixing electro-mechanical devices (e.g., motors and pumps), with familiarity in common hand tools, diagnostic tools (e.g., multimeters, vibration analyzers), and techniques for condition-based monitoringProven track record in equipment reliability analysis, such as failure mode and effects analysis (FMEA) or root cause analysis, leading to measurable predictive maintenance successesProven interpersonal skills and ability to objectively resolve conflict within a large groupAble to work flexible hours and schedules as required and a passion for tackling challenging engineering problems, with a drive to innovate and grow in a dynamic, high-impact settingCompensation & BenefitsBenefitsAlong 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 deductionFamily-building, fertility, adoption and surrogacy benefitsDental (including orthodontic coverage) and vision plans, both have options with a $0 paycheck contributionCompany Paid (Health Savings Accounts) HSA Contribution when enrolled in the High-Deductible medical plan with HSAHealthcare and Dependent Care Flexible Spending Accounts (FSA)401(k) with employer match, Employee Stock Purchase Plans, and other financial benefitsCompany paid Basic Life, AD&DShort-term and long-term disability insurance (90 day waiting period)Employee Assistance ProgramSick and Vacation time (Flex time for salary positions, Accrued hours for Hourly positions), and Paid HolidaysBack-up childcare and parenting support resourcesVoluntary benefits to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insuranceWeight Loss and Tobacco Cessation ProgramsTesla Babies programCommuter benefitsEmployee discounts and perks programExpected Compensation $91,600 - $195,600/annual salary + cash and stock awards + benefitsPay offered may vary depending on multiple individualized factors, including market location, job-related knowledge, skills, and experience. The total compensation package for this position may also include other elements dependent on the position offered. Details of participation in these benefit plans will be provided if an employee receives an offer of employment.