Automated Controls Engineer: PLCs, Robots & Vision

Insight Global

Saginaw (MI)

On-site

USD 85,000 - 120,000

Full time

1 hour ago

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Job summary

Insight Global in Michigan partners with automakers to deliver advanced automation solutions. This role focuses on developing, modifying, and debugging PLC and HMI programs for high-volume manufacturing equipment.

You will program FANUC and CRX robots, design machine-vision systems, validate sensors and safety circuits, and support installation, commissioning, and rigorous testing. Collaboration across manufacturing, controls, quality, and maintenance is essential.

Qualifications

3+ years as a Controls Engineer in automotive/high-volume manufacturing.
Experience supporting General Motors facilities or automation providers following GM standards.
GCCS/GCCH certification and hardware experience.
Strong knowledge of GM controls standards and assembly line automation.
Hands-on programming, troubleshooting, and support of PLC-based automation on the plant floor.
Experience with Siemens Step 7 and/or Rockwell PLCs.
Familiarity with FACS, EtherNet/IP, and industrial protocols.
Experience with FANUC robots and basic robot fault troubleshooting.
Experience with Cognex and/or Keyence vision systems.
Knowledge of industrial networks, robot integration, HMIs, and controls architecture.
Familiarity with CITI Logic and G-Comply processes.

Responsibilities

Develop, modify, troubleshoot, and support PLC and HMI programs for automated manufacturing equipment and production systems.
Program, configure, and optimize FANUC industrial robots and CRX collaborative robots for assembly, material handling, inspection, or process automation applications.
Design, integrate, and validate machine vision systems for inspection, guidance, part verification, and process control.
Perform sensor, I/O, and safety validation activities including troubleshooting field devices, safety circuits, interlocks, and network communications.
Support equipment installation, startup, debugging, and commissioning activities at manufacturing facilities.
Ensure automation systems comply with GM automation standards (GCCS/GCCH) and customer specifications.
Collaborate with manufacturing, controls, quality, and maintenance teams to resolve production issues and improve equipment performance.
Conduct system testing, FATs, SATs, and production readiness reviews prior to launch.
Troubleshoot PLC, robot, vision, networking, and electrical issues to minimize downtime and support manufacturing operations.
Create and maintain controls documentation including electrical schematics, I/O lists, safety validation reports, and operating procedures.
Support continuous improvement initiatives focused on throughput, quality, reliability, and automation performance.