Lead Engineer - Controls

General Motors (GM); Bengaluru; On-site; INR 1,200,000 - 1,800,000; Full time

Benefits offered by this job

Travel opportunities

GM Global standards training

Job summary

General Motors India at Bengaluru’s Technical Centre is seeking a seasoned Controls Engineer to lead hardware/software design, emulation, and on-site integration across GM plants. The role blends execution and development with travel opportunities and cross-regional collaboration.

Ideal candidates will have 10+ years in automotive or automation, strong control systems knowledge, and proficiency with Rockwell PLC, Siemens HMI, Emulate 3D, and Robot programming.

Qualifications

• Masters/ bachelor's degree in electrical/electronics/instrumentation engineering.
• 10+ years in automotive or software companies with automation background.
• Strong knowledge of control systems in automotive assembly plants.
• Proficient in PLC, HMI, drives, networks; Rockwell PLC preferred.
• Experience in project management and site execution.
• Knowledge of Rockwell PLC software and Siemens HMI; interfaces to other controls systems.
• Familiarity with Emulate 3D and machine vision hardware/software.
• Experience with robot programming (FANUC) and robot applications.
• Ability to read electrical/mechanical drawings and design capabilities.
• Understanding of EPLAN for hardware design; Siemens HMI advantageous.

Responsibilities

• Supervise and control projects, define scope, risks, and schedules; report progress.
• Participate in investment studies and design discussions for new/expansion projects.
• In-house hardware/software design, emulation, and site integration.
• For turnkey projects, approve hardware/software designs and conduct offline testing at supplier sites.
• Implement GM global design tools to minimize on-site debugging; train suppliers and engineers.
• Validate designs and ensure GM standards are met across projects.
• Deploy GM global standards and train suppliers to adhere to them.
• Conduct root-cause analyses and share lessons learned from projects.
• Coordinate timing, deliverables, and safety with teams; run test runs at site.
• Collaborate with GM units worldwide on global projects.
• Develop and maintain Emulate 3D models (Electrical/Mechanical).
• Develop Electrical/Mechanical models using Emulate 3D.

Skills

Electrical engineering

Automation

Rockwell PLC

Siemens HMI

Project management

Emulate 3D

Robot programming

Mechanical drawings

XML/C#/Python

Travel readiness

Education

Masters/Bachelors in Electrical/Electronics/Instrumentation

Tools

Emulate 3D

EPLAN

Rockwell PLC Software

Siemens HMI

Matrox Machine Vision

Job description

Work Arrangement

This role is categorized as hybrid. This means the successful candidate is expected to report to the office four times per week or other frequency dictated by the;business.

The Role

This position is based at GM Technical Centre India - Bengaluru, where our teams focus on manufacturing engineering in Automation. We specialize in designing, developing and operationalizing complex integrated production systems to deliver cost-effective solutions with highest standards of quality.

Automation work categorize into 2 types, Execution Development.;

During Execution role, The Controls engineer will be primarily responsible for execution of all Controls related projects in various capacities at GM plants across the Globe with respect to Safety, Delivery, Quality, Cost and Performance. In this position the Engineer will perform offline designs and online execution on various new or existing product programs across our portfolio. The incumbent will need to possess a broad technical knowledge, combined with creative and independent thinking and conceptual ability.;

During Developmental role, the Controls Engineer will be responsible to work along with Regional Global team/SMEs to develop maintain engineering standards work related to Hardware/Software templates, e-tools, etc.;

This position will be based out of GM Technical Center India in Bangalore and involves travel opportunities across different regions for project execution.

What You'll Do

• Supervise and control projects including project scope, issues, risks and schedule. Handle issues to closure. Communicate project status and ensures all internal customers are aware of progress through project meetings, status reports and reviews.
• Participate in Investment studies, preliminary design discussions for any new or expansion projects.
• Responsible for inhouse engineering on Hardware designs, software designs, Emulation, Integration Commissioning at site.
• If its Turnkey project, Guide approve Hardware/ Software designs done by contractors for various project in the region. Conduct offline testing Buyoff at suppliers site.
• Implement GM Global tools for design of hardware software to ensure minimum debug on site. Train suppliers and Engineers of other GM units.
• Validate designs and provide feedback to Global Centre w.r.t GM standards.
• Responsible for deploying GM Global standards across all projects.
• Responsible for training and Integrating Suppliers to enforce to GM standards.
• Responsible for performing Root cause analysis.
• Prepare Share lessons learnt for the projects completed.
• Coordinate project timing schedule, design deliverables and safety aspects with team. Jointly conduct test runs for equipment at site as per process.
• Coordination with other units of GM (worldwide) for Global projects.
• Develop Maintain components in Emulate 3D (Electrical Mechanical)
• Develop Electrical Mechanical models using Emulate 3D
• Thorough knowledge of Plant Floor System related to Automation.

Your Skills Abilities (Required Qualifications)

• Masters/ bachelor's degree in electrical engineering / Electronics Engineering / Instrumentation Engineering.
• 10+ years' experience in any Automotive companies or Software Companies with Automation background.
• In depth knowledge of control systems and/or control systems in automotive assembly plants
• Knowledge on PLC, HMI, Drives, Networks along with strong programming skills preferably Rockwell PLC.
• Project management and site execution skills.
• Thorough knowledge of Rockwell PLC software, Siemens HMI software as well as interfaces to other controls systems
• Knowledge of Emulation softwares like Emulate 3D, etc
• Knowledge of Machine Vision hardwares/softwares (Matrox)
• Thorough knowledge of PLC hardware and software design and engineering
• Knowledge of design for health and safety will be helpful
• Knowledge on equipment selection, cost estimation, material procurement is an advantage
• Should be able to read Electrical/mechanical drawings, layout and have design capabilities.
• Acquaintance with Eplan for hardware design and experience on Siemens HMI will be an added advantage.
• Ability to understand legacy equipment propose solutions in case of upgradation.
• Knowledge of interface to upper level systems.
• Basic Knowledge on programming skills such as XML, C#, J Script, VBA, Python etc..
• Knowledge on Robot Programming and troubleshooting, preferably FANUC Robots
• Knowledge on Robotic applications like spot-welding, arc-welding, dispensing, roller hemming etc.
• Acquaintance with Robot simulation studies and experience on Robot simulation software will be an added advantage.
• Robot interface with other equipment (PLC, Line Controller, Other Machines etc). Experience in large BIW projects. Ability to understand electrical and electronic requirements for mechanical equipments.

What Will Give You A Competitive Edge (Preferred Qualifications)

• Good communication and interpersonal skills.
• Quick Learning functional expertise.
• Project management and site execution skills
• Ability to work with intercultural, multi-disciplinary remote teams to achieve functional goals.
• Ability to organize, plan, prioritize and execute projects;with a keen attention to details.
• Willingness to travel across regions for executing projects.
• In-House Hardware and Software controls experience is preferred