Process Modeling & Control Engineer, Cell Engineering

Tesla-posted 8 months ago
$80,000 - $174,000/Yr
Full-time • Mid Level
Fremont, CA
Transportation Equipment Manufacturing
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As Tesla continues to vertically integrate our operations, Tesla's in-house cell group is looking for a highly motivated Process Modelling and Control Engineer to work on a critical challenge facing the world's energy transition. As a process control and modeling engineer, you will work closely with the process development, equipment and mechanical design team to drive the development, optimization, and control of advanced cell manufacturing processes, ensuring robust, efficient, and scalable production systems. You will be at the forefront of process innovation, combining control system expertise with process modeling to support the factory ramp and deliver world-class battery technology. This role involves close partnership with teams to transition new processes from initial design and prototyping to full-scale production.

  • Work closely with the process design and operations teams to develop dynamic simulations of process equipment and production facilities.
  • Develop simulations to test control logic using a digital twin concept.
  • Work closely with process engineers and use simulation results to inform equipment design.
  • Simulate process upset scenarios to understand the limitations of the process.
  • Program and debug structured text and ladder logic code to configure control systems for automation equipment, utilizing multiple PLC platforms (e.g., Beckhoff TwinCAT, Siemens TIA Portal) to manage motion controls, data acquisition systems, and PID controllers for precise process regulation.
  • Develop and validate process models (e.g., physics-based, data-driven, or hybrid models) to simulate and improve cell manufacturing processes.
  • Design and simulate mechanical components or subsystems using CAD tools (e.g., SolidWorks, CATIA) to support process modeling and equipment performance optimization.
  • Develop code that is organized, structured, documented, maintainable and reusable, using Python scripting and SQL to interface equipment with Tesla Manufacturing Execution System (MES) and to collect data into production databases.
  • Create intuitive operator touchscreen interfaces using TwinCAT HMI/WinCC and SCADA dashboards screens using Ignition.
  • Set up and tune servo drives and VFDs for fast and smooth operation (Beckhoff, Siemens, SEW).
  • Introduce automated processes into production, and train and equip Sustaining Team to support automated equipment after deployment into production.
  • Establish test plans and control test plan execution.
  • Debug and optimize automated processes to maximize cycle time and uptime.
  • Manage the network and hardware IT infrastructure.
  • 5+ years as a process controls and modeling engineer or as a dynamic simulation engineer.
  • Bachelor's Degree in Electrical, Mechanical or Mechatronics Engineering, Chemistry, or equivalent experience.
  • Evidence of exceptional ability, including a strong understanding of engineering fundamentals and demonstrated ability to leverage this understanding to solve challenging technical problems.
  • Strong background in process modeling and simulation tools (e.g., MATLAB/Simulink, Aspen, COMSOL, FEM, Ansys or similar) applied to manufacturing or chemical processes.
  • Proficiency in programming industrial control systems using IEC 61131-3 languages (e.g., structured text, ladder logic) and experience with platforms like Beckhoff, Siemens, or Omron.
  • Analytical mindset with a proven ability to use data to optimize processes and solve complex engineering challenges.
  • Proficiency in field network topology, both theory and practical applications.
  • Fluent in multiple coding languages (minimum: MatLab, Python).
  • Previous experience with modeling different unit operations involved with cell manufacturing.
  • Understanding of databases and various programming languages (Java, Python).
  • HMI programming experience - TwinCAT HMI, WinCC and Ignition.
  • Robotic programming skills.
  • Vision systems.
  • Aetna PPO and HSA plans > 2 medical plan options with $0 payroll deduction.
  • Family-building, fertility, adoption and surrogacy benefits.
  • Dental (including orthodontic coverage) and vision plans, both have options with a $0 paycheck contribution.
  • Company Paid (Health Savings Account) HSA Contribution when enrolled in the High Deductible Aetna medical plan with HSA.
  • Healthcare and Dependent Care Flexible Spending Accounts (FSA).
  • 401(k) with employer match, Employee Stock Purchase Plans, and other financial benefits.
  • Company paid Basic Life, AD&D, short-term and long-term disability insurance.
  • Employee Assistance Program.
  • Sick and Vacation time (Flex time for salary positions), and Paid Holidays.
  • Back-up childcare and parenting support resources.
  • Voluntary benefits to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance.
  • Weight Loss and Tobacco Cessation Programs.
  • Tesla Babies program.
  • Commuter benefits.
  • Employee discounts and perks program.
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