Controls Engineer

Insight Global; Saginaw (MI); On-site; USD 85,000 - 120,000; Full time

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.

Skills

PLC programming

Robot integration

Industrial networking

Vision systems

Safety validation

GM GCCS/GCCH standards

GM standards

Tools

Siemens Step7

Rockwell/Allen-Bradley PLCs

FANUC robots

Cognex vision

Keyence vision

EtherNet/IP

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.

Required Skills and Experience

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.