Controls Engineer
General Motors
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Job summary
General Motors is seeking a Controls Engineer to lead and support manufacturing automation systems, ensuring safety, quality, and throughput. The role involves hands-on electrical controls work, system integration, and continuous improvement across production lines.
You will develop and optimize PLC/HMI programs, support VFDs and robotic systems, and collaborate with maintenance, engineering, and leadership to deliver reliable equipment and safe operations.
Qualifications
- Bachelor's degree in Electrical Engineering or equivalent.
- 3+ years of manufacturing engineering for automated production.
- Strong troubleshooting and complex automation problem solving.
- Experience with PLC-based control systems and Allen-Bradley platforms.
Responsibilities
- Provide controls engineering and electrical support for manufacturing operations.
- Troubleshoot and resolve automation, controls, and process issues.
- Develop and optimize PLC, HMI, drive, robot, and vision programs.
- Lead safety, risk assessments, and compliance initiatives.
- Design and implement control system improvements for safety and reliability.
Skills
Education
Tools
Job description
Job Description The Controls Engineer is responsible for providing technical leadership and support for manufacturing automation systems, production equipment, and electrical controls infrastructure. This role supports safe and efficient manufacturing operations through troubleshooting, continuous improvement, system integration, launch support, and maintenance coordination. The Controls Engineer works closely with production, maintenance, skilled trades, manufacturing engineering, and plant leadership to ensure system reliability, safety, quality, and throughput objectives are achieved. The successful candidate will be a hands-on technical leader who thrives in a fast-paced manufacturing environment, demonstrates strong problem-solving skills, and drives continuous improvement through automation, innovation, and collaboration.
Promote and enforce safe work practices as the highest priority in all activities. Ensure all controls modifications and automation changes comply with corporate and plant safety standards. Support lockout/tagout compliance, machine safeguarding initiatives, risk assessments, and safety investigations. Participate in safety reviews and support continuous improvement of manufacturing safety systems.
Provide controls engineering and electrical support for manufacturing operations. Troubleshoot and resolve complex automation, controls, equipment, and process-related issues. Lead root cause analysis activities and implement permanent corrective actions to prevent recurring failures. Provide technical direction and troubleshooting support to production, maintenance, and skilled trades personnel. Develop, modify, maintain, and optimize PLC, HMI, drive, robot, vision, and automation system programs. Support variable frequency drives, motor controls, industrial networks, and electrical systems throughout the facility. Maintain controls documentation, electrical drawings, and program backups.
Design and implement control system improvements that enhance safety, quality, productivity, and equipment reliability. Support production departments by identifying and eliminating performance constraints. Implement and maintain error-proofing systems, including SEP, EPP, vision systems, barcode applications, and traceability solutions. Drive continuous improvement initiatives focused on reducing downtime, improving throughput, and increasing operational efficiency. Support quality investigations and corrective action activities related to automation and control systems.
Plant floor-to-enterprise system integration and manufacturing data communications. Troubleshoot and maintain industrial communication networks including Ethernet/IP, DeviceNet, ControlNet, and related technologies. Support manufacturing execution systems, traceability systems, and plant floor software applications. Evaluate and implement new automation technologies and innovative manufacturing solutions.
Support equipment installations, launch activities, model year changes, and production startups. Participate in planning activities for future equipment, capacity expansion, and manufacturing process improvements. Lead controls-related projects from concept through implementation and startup. Coordinate suppliers, contractors, and cross-functional teams during project execution. Ensure systems meet safety, quality, and production requirements prior to launch approval.
Provide technical guidance, coaching, and training to maintenance personnel and skilled trades. Coordinate and direct maintenance activities requiring controls engineering support. Build strong partnerships with production personnel, maintenance teams, engineering groups, suppliers, and leadership. Demonstrate ownership and accountability by driving issues to closure and effectively communicating progress and results.
- Bachelor's Degree in Electrical Engineering, Computer Engineering, Computer Science, Mechatronics Engineering, or equivalent technical experience.
- Minimum of 3 years of manufacturing engineering experience supporting automated production systems, controls, robotics, industrial automation, or related technical disciplines.
- Demonstrated ability to troubleshoot and resolve complex manufacturing and automation system issues.
- Strong analytical thinking and creative problem-solving abilities.
- Excellent interpersonal and communication skills with the ability to effectively collaborate with hourly employees, skilled trades, engineers, suppliers, and leadership.
- Strong self-motivation, initiative, and work ethic.
- Ability to work all shifts and support weekend activities as business needs require.
- Ability to effectively manage multiple priorities in a fast-paced manufacturing environment.
- Understanding of manufacturing processes, tooling systems, and automated production equipment.
- Experience programming and troubleshooting PLC-based control systems, particularly Allen-Bradley/Rockwell platforms.
- Experience supporting Variable Frequency Drives (VFDs), especially Allen-Bradley PowerFlex drives.
- Ability to read, interpret, and troubleshoot electrical schematics, wiring diagrams, and control drawings.
- Experience with industrial communication networks such as Ethernet/IP, DeviceNet, ControlNet, and related automation protocols.
- Experience supporting HMI and operator interface systems, including Allen-Bradley and Siemens platforms.
- Knowledge of machine vision systems, inspection strategies, and industrial automation technologies.
- Experience implementing and maintaining error-proofing solutions in a manufacturing environment.
- Proficiency with Microsoft Office applications and Microsoft Teams.
- Flexibility to adapt quickly as priorities and business needs change.
- Experience programming and supporting industrial robots, particularly FANUC robots.
- Experience with machine vision systems including Cognex and Matrox platforms.
- Knowledge of conveyor systems, automated material handling systems, and manufacturing conveyance technologies.
- Experience with AutoCAD, EPLAN, or equivalent electrical design software.
- Experience supporting dispense systems, paint applications, weld tooling, or automated process equipment.
- Experience with GM plant floor systems, including EPP, SEP, GEPICS, GPMC, GSIP, EPS, PPS, PR&T, Andon, and GE Cimplicity.
- Knowledge of wireless manufacturing technologies, RF systems, and tracking applications.
- Experience with Octoplant automated backup and change management systems.
- Experience supporting Allen-Bradley ArmorStart and distributed motor control systems.
- Experience with manufacturing data collection, traceability systems, MES integration, and factory information systems.
- Prior automotive manufacturing experience.
The successful candidate will:
- Maintain safety as the highest priority in all controls engineering activities.
- Support equipment and production systems that consistently meet plant safety, quality, throughput, and reliability objectives.
- Minimize production downtime through effective troubleshooting, root cause analysis, and implementation of permanent corrective actions.
- Deliver controls-related projects, launches, and process improvements on schedule and with minimal production disruption.
- Develop and implement automation solutions that improve equipment reliability, productivity, quality, and maintainability.
- Identify and execute continuous improvement opportunities that provide measurable operational benefits.
- Maintain accurate controls documentation, program backups, and change management records.
- Build strong working relationships with operations, maintenance, skilled trades, engineering, and plant leadership teams.
- Serve as a trusted technical resource and subject matter expert for manufacturing automation and controls systems.
- Demonstrate ownership, accountability, and leadership by driving issues to closure and delivering sustainable results.
GM does not provide immigration-related sponsorship for this role.
Do not apply for this role if you will need GM immigration sponsorship now or in the future. This includes direct company sponsorship, entry of GM as the immigration employer of record on a government form, and any work authorization requiring a written submission or other immigration support from the company (e.g., H1-B, OPT, STEM OPT, CPT, TN, J-1, etc).
This role is categorized as onsite. This means the selected candidate is expected to report to a specific location on a full-time basis.
This job may be eligible for relocation benefits.
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