Controls Engineer

Insight Global; Detroit (MI); On-site; USD 62,000 - 73,000; Full time

Benefits offered by this job

Medical, dental, and vision insurance

HSA, FSA, and DCFSA options

401k with employer matching

Paid time off and sick leave

Job summary

Insight Global is seeking a Controls Engineer to support high‑volume automotive automation initiatives. You will program PLC/HMI, integrate FANUC and CRX robots, and validate machine vision systems on the plant floor.

The role requires hands-on troubleshooting, safety validation, and collaboration with manufacturing, quality, and maintenance teams to boost throughput and reliability within an GM standards framework.

Qualifications

• 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/GCCH 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.

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 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.

Skills

PLC programming

HMI programming

Robot integration

Machine vision systems

Field troubleshooting

Industrial networking

Safety validation

GM standards knowledge

FANUC robotics

CRX robotics

Education

Bachelor's degree in Electrical Engineering or Automation

Tools

FANUC robots

CRX collaborative robots

Siemens Step 7

Rockwell Allen-Bradley PLCs

Cognex vision systems

Keyence vision systems

EtherNet/IP

Job description

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.

Compensation: $45/hr to $53/hr. Exact compensation may vary based on several factors, including skills, experience, and education.

Benefit packages for this role will start on the 1st 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

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.

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 opportunity/affirmative action employer that believes everyone matters. Qualified candidates will receive consideration for employment regardless of their 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.

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