Controls Engineer

Insight Global; Buffalo (NY); On-site; USD 55,000 - 80,000; Full time

Benefits offered by this job

Medical Insurance

Dental Insurance

Vision Insurance

HSA

FSA

DCFSA

401k matching

Paid sick leave

Job summary

Insight Global seeks a seasoned Controls Engineer to develop and support PLC/HMI programs, configure FANUC and CRX robotics for automated manufacturing, and design machine vision for inspection and process control.

You will validate sensors, safety circuits, and network communications while collaborating with manufacturing teams to resolve issues and launch improvements. Equal opportunity employer and onboarding began with comprehensive benefits.

Qualifications

• Bachelor's degree in Electrical Engineering, Controls Engineering, Mechatronics Engineering, or related field.
• 3+ years of experience as a Controls Engineer in automotive/high-volume manufacturing.
• Hands-on experience programming, troubleshooting, and supporting automation systems on the plant floor.
• Familiarity with GM controls standards and manufacturing processes.
• Experience with GCCH (hardware) and GCCS (software) standards.
• Ability to support automation equipment commissioning and continuous improvement.
• Strong knowledge of PLCs, HMIs, industrial networks, and robot integration.
• Experience with Allen-Bradley ControlLogix, Studio 5000, FactoryTalk, Siemens TIA Portal, or equivalent platforms.
• Knowledge of safety standards including Lockout/Tagout and machine safeguarding.

Responsibilities

• Develop, modify, troubleshoot, and support PLC and HMI programs for automated equipment.
• Program and optimize FANUC and CRX robots for assembly and automation.
• Design and validate machine vision systems for inspection and verification.
• Validate sensors, I/O, safety circuits, interlocks, and network communications.
• Support installation, startup, and commissioning at facilities.
• Ensure automation meets GM GCCS/GCCH and customer specs.
• Collaborate with production teams to resolve downtime and improve performance.
• Conduct FATs, SATs, and production readiness reviews.
• Create controls documentation including schematics and I/O lists.
• Drive continuous improvement in throughput, quality, and reliability.

Skills

PLC programming

Robot integration

Machine vision

Industrial networking

Safety validation

FANUC robot programming

Rockwell/Studio 5000

Siemens Step 7

Cognex/Keyence vision

Ethernet/IP networking

Education

Bachelor's degree in Electrical Engineering / Controls / Mechatronics

Tools

Rockwell Studio 5000

Siemens TIA Portal

GCCS/GCCH standards knowledge

Cognex/Keyence Matrox vision tools

Job description

Job Description

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 (CRX30i preferred) 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 General Motors 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.

$40/hr to $58/hrExact compensation may vary based on several factors, including skills, experience, and education.

Benefit packages for this role will start on the 31st day of employment and include medical, dental, and vision insurance, as well as HSA, FSA, and DCFSA account options, and 401k retirement account access with employer matching. Employees in this role are also entitled to paid sick leave and/or other paid time off as provided by applicable law.

Skills and Requirements

• Bachelor's degree in Electrical Engineering, Controls Engineering, Mechatronics Engineering, or a related field.
• 3+ years of experience as a Controls Engineer in an automotive or high-volume manufacturing environment.
• Hands-on experience programming, troubleshooting, and supporting industrial automation systems and robots on the plant floor.
• Familiarity with GM controls standards and manufacturing processes.
• Experience working for General Motors or a similar automation company supporting GM facilities/standards.
• Experience with GCCH (hardware) and/or GSSC/GCCS (software) standards.
• Ability to support automation equipment commissioning, debugging, and continuous improvement initiatives in a production environment.
• Strong understanding of PLCs, HMIs, industrial networks, and robot integration.Familiar with FACSExperience in GCCH, GCCS, Ethernet IP NetworkingSiemens Step 7 PLC / Rockwell Allen Bradley PLCAssembly line experience.CITI Logic experience.Cognex and Keyence, Matrox vision experience.Able to recover basic Fanuc robot faultsFamiliarity with G-comply process, preparing TIS / SCS Electrical task.
• Experience with Allen-Bradley ControlLogix, Studio 5000, FactoryTalk, Siemens TIA Portal, or equivalent controls platforms
• Knowledge of industrial safety standards including Lockout/Tagout, machine safeguarding, and safety PLC systems
• Experience with automotive assembly, battery manufacturing, powertrain, body shop, or material handling automation
• Previous commissioning or launch support experience within OEM or Tier 1 manufacturing environments

We are a company committed to creating diverse and inclusive environments where people can bring their full, authentic selves to work every day. We are an equal employment opportunity/affirmative action employer that believes everyone matters. Qualified candidates will receive consideration for employment without regard to race, color, ethnicity, religion, sex (including pregnancy), sexual orientation, gender identity and expression, marital status, national origin, ancestry, genetic factors, age, disability, protected veteran status, military or uniformed service member status, or any other status or characteristic protected by applicable laws, regulations, and ordinances. If you need assistance and/or a reasonable accommodation due to a disability during the application or the recruiting process, please send a request to [e-mail].