Controls Engineer

Insight Global; City of Tonawanda (NY); On-site; USD 114,616,000 - 149,001,000; Full time

Benefits offered by this job

Medical insurance

Dental insurance

Vision insurance

HSA/FSA/DCFSA accounts

401k with employer matching

Paid sick leave/ PTO

Job summary

Insight Global seeks a Controls Engineer to support advanced manufacturing automation in a high-volume automotive environment. You will handle PLC/HMI programming, robot and vision system integration, startup and commissioning activities, and validation of automated manufacturing systems.

The ideal candidate will have hands-on experience with FANUC and CRX robots, machine vision systems, and automotive automation standards.

Qualifications

• 3+ years as a Controls Engineer in automotive or high-volume manufacturing.
• Experience supporting GM facilities or automation for GM standards.
• GCCS/GSSC certification and GCCH hardware experience.
• Strong knowledge of GM controls standards, manufacturing processes, and assembly line automation.
• Hands-on programming, troubleshooting, and support of PLC-based automation on the plant floor.
• Experience with Siemens Step 7 PLCs and/or Rockwell/Allen-Bradley PLCs.
• Familiarity with FACS, EtherNet/IP, and industrial protocols.
• Experience commissioning automation equipment and driving continuous improvement.
• Experience with FANUC robots and CRX collaborative robots.

Responsibilities

• Develop, modify, troubleshoot, and support PLC and HMI programs for automated equipment.
• Program, configure, and optimize FANUC and CRX robots for assembly, handling, inspection, or automation.
• Design, integrate, and validate machine vision systems for inspection and process control.
• Perform sensor, I/O, and safety validation including diagnostics of networks and interlocks.
• Support equipment installation, startup, debugging, and commissioning at facilities.
• Ensure automation systems comply with GM GCCS/GCCH standards and customer specs.
• Collaborate with manufacturing, controls, quality, and maintenance teams to resolve issues.
• Conduct FATs/SATs and production readiness reviews before launch.
• Troubleshoot PLC, robot, vision, networking, and electrical issues to minimize downtime.
• Create and maintain controls documentation (schematics, I/O lists, procedures).
• Support continuous improvement focused on throughput, quality, reliability, and automation performance.

Skills

Controls engineering

GM manufacturing

Industrial networking

Troubleshooting

Robot integration

Education

GCCS/GSSC certification

Tools

Siemens Step7

Rockwell/Allen-Bradley PLCs

FANUC robots

CRX robots

Machine vision (Cognex/Keyence)

HMI programming

Job description

Duration: 9 months-1 year contract with possible extensions

Travel: Some travel to Canada when needed (only for Tonawanda possibly Romulus)

Shift: 6:00am-6:00pm

Compensation: $40/hr to $52/hr

Exact 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.

Must Haves:

• 3+ years of experience as a Controls Engineer in an automotive or high-volume manufacturing environment.
• Experience supporting General Motors manufacturing facilities or working for an automation company supporting GM standards.
• GCCS/GSSC certification and experience with GCCH (hardware)
• Strong knowledge of GM controls standards, manufacturing processes, and assembly line automation.
• Hands-on experience programming, troubleshooting, and supporting PLC-based automation systems on the plant floor.
• Experience with Siemens Step 7 PLCs and/or Rockwell Allen-Bradley PLCs.
• Familiarity with FACS, EtherNet/IP networking, and industrial communication protocols.
• Experience supporting automation equipment commissioning, debugging, and continuous improvement initiatives in a production environment.
• Experience with Fanuc robots, including troubleshooting and recovering basic robot faults.
• Experience with Cognex and/or Keyence vision systems.
• Strong understanding of industrial networks, robot integration, HMIs, and controls architecture.
• Familiarity with CITI Logic, G-Comply processes, and preparing TIS/SCS electrical tasks.

Job Description:

Insight Global is looking for a Controls Engineer to support advanced manufacturing automation initiatives within a high-volume automotive environment. This position will be responsible for PLC and HMI programming, robot and vision system integration, startup and commissioning activities, and validation of automated manufacturing systems. The ideal candidate will have experience working with FANUC robots and CRX collaborative robots, machine vision systems, and automotive automation standards.

• 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.