Manufacturing Controls Engineering Lead

General Motors; Bedford (IN); On-site; USD 110,000 - 160,000; Full time

Job summary

General Motors Bedford casting operations seeks a seasoned Controls Engineering leader to guide a team in developing, implementing, and improving industrial control systems. You will partner with manufacturing engineering, maintenance, operations, quality, IT, and suppliers to boost safety, quality, delivery, cost, throughput, and equipment reliability.

You will solve complex problems, review hardware and software changes, and drive projects from scoping to execution, including device level

Qualifications

• Bachelor's degree in a related engineering field or equivalent hands-on experience.
• 5+ years in controls engineering, automation engineering, robotics engineering, or manufacturing systems integration.
• Strong knowledge of industrial control systems in a manufacturing environment.
• Experience with PLC and HMI programming, industrial networking, and troubleshooting.

Responsibilities

• Provide technical support and direction for controls, automation, IT, maintenance, and skilled trades partners.
• Lead troubleshooting and root-cause analysis for PLC, HMI, drive, network, safety, and equipment-control issues; follow actions through closure.
• Lead controls planning and execution for die-casting, machining, melting, material handling, and plant improvement projects.
• Review and guide hardware designs, software changes, controls architecture, testing, commissioning, buyoff, and documentation.
• Coordinate with area manufacturing engineers on process changes, equipment planning, model change, throughput, sourcing, and project timing.
• Develop project scopes, schedules, cost estimates, investment forecasts, business cases, appropriation requests, and execution plans.
• Support Device Level Analytics and related plant digital initiatives through PLC configuration, device onboarding, data validation, health checks, and training.
• Apply GM controls, electrical, safety, lockout, ESWP, and equipment buyoff standards; ensure safe work practices are the highest priority.
• Use data and statistical problem-solving methods to improve equipment availability, cycle time, quality, capacity, and cost.
• Maintain effective working relationships with plant leadership, hourly employees, union partners, suppliers, contractors, and technical organizations.
• Lead a team of controls engineers and share lessons learned, standards, and best practices across the Bedford controls team.

Skills

Controls engineering

Automation engineering

Robotics engineering

Manufacturing systems integration

PLC programming

HMI programming

Education

Bachelor's degree in Electrical/Mechanical/Computer Engineering or Robotics

Tools

Allen-Bradley

Siemens

Industrial Ethernet

Job description

Job Description Job Description In this role, you will lead a team of Controls Engineers for the development, implementation, troubleshooting, and continuous improvement of industrial controls systems supporting GM Bedford’s casting operations. You will partner with manufacturing engineering, maintenance, operations, quality, IT, suppliers, and plant leadership to improve safety, quality, delivery, cost, throughput, and equipment reliability. You will lead a team to solve diverse, non-standard problems; develop practical solutions with limited precedent; and influence decisions across the plant through technical expertise, data, and collaboration.

Responsibilities

Provide technical support and direction for controls, automation, IT, maintenance, and skilled‑trades partners.

Lead troubleshooting and root‑cause analysis for PLC, HMI, drive, network, safety, and equipment‑control issues; follow actions through closure.

Lead controls planning and execution for die‑casting, machining, melting, material handling, and plant improvement projects.

Review and guide hardware designs, software changes, controls architecture, testing, commissioning, buyoff, and documentation.

Coordinate with area manufacturing engineers on process changes, equipment planning, model change, throughput, sourcing, and project timing.

Develop project scopes, schedules, cost estimates, investment forecasts, business cases, appropriation requests, and execution plans.

Support Device Level Analytics and related plant digital initiatives through PLC configuration, device onboarding, data validation, health checks, and training.

Apply GM controls, electrical, safety, lockout, ESWP, and equipment buyoff standards; ensure safe work practices are the highest priority.

Use data and statistical problem‑solving methods to improve equipment availability, cycle time, quality, capacity, and cost.

Maintain effective working relationships with plant leadership, hourly employees, union partners, suppliers, contractors, and technical organizations.

Lead a team of controls engineers and share lessons learned, standards, and best practices across the Bedford controls team.

Required Qualifications

• Bachelor’s degree in Electrical Engineering, Mechanical Engineering, Computer Engineering, Robotics, or a related technical field, or equivalent hands‑on technical experience.
• 5+ years of experience in controls engineering, automation engineering, robotics engineering, or manufacturing systems integration.
• Strong knowledge of industrial control systems and the ability to apply that knowledge in a manufacturing or production environment.
• Experience with PLC and HMI programming, industrial networking, and controls system troubleshooting.
• Strong analytical, problem‑solving, and communication skills.

Preferred Qualifications

• Demonstrated technical leadership experience integrating or supporting robotics, automated equipment, or advanced manufacturing systems.
• Experience supporting equipment buyoff, installation, launch, commissioning, and production startup.
• Experience with Allen‑Bradley, Siemens, industrial Ethernet, and related plant‑floor communication interfaces.
• Experience with machine vision, vision‑guided robotics, automated inspection, or error‑proofing systems.
• Experience influencing technical decisions, leading others, and driving improvements beyond an immediate assignment area.
• Familiarity with manufacturing safety systems and safe automation design practices.
• Experience working directly with suppliers, system integrators, and cross‑functional plant teams.

About GM

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