Senior Controls Engineer- Body Shop

General Motors; Lake Orion (MI); On-site; USD 90,000 - 130,000; Full time

Job summary

General Motors in Orion, Michigan is seeking a 2nd shift Senior Controls Engineer to lead controls strategy for body shop manufacturing systems and to serve as the technical authority for PLC, robotics, and network architecture standards.

You will manage complex electrical and controls projects, develop cost estimates, and provide technical mentorship across shifts while focusing on safety, reliability, and cost efficiency.

Qualifications

• Advanced ability to program, troubleshoot, and optimize Rockwell/Allen-Bradley ControlLogix PLC systems in high-volume automotive manufacturing environments.
• Advanced troubleshooting and programming experience with FANUC robotic systems, including robot path recovery, fault diagnostics, and production optimization.
• Strong understanding of welding systems, weld controllers, weld schedules, and robotic welding applications.
• Expert ability to read, interpret, and modify electrical schematic and controls documentation.
• Advanced troubleshooting experience with automated body shop manufacturing systems, material handling equipment, and conveyor controls.
• Strong knowledge of industrial communication networks including Ethernet/IP, DeviceNet, ControlNet, and integrated robot-to-PLC communication.
• Experience supporting safety-rated control systems, robot safety zones, interlocks, and machine safeguarding requirements.
• Strong analytical and structured problem-solving capabilities utilizing root cause analysis and data-driven methodologies.
• Effective leadership, communication, and interpersonal skills with the ability to influence cross-functional teams.
• Willingness to work 2nd shift
• Willingness to support weekend or extended hours during critical production and project phases.

Responsibilities

• Lead controls engineering strategy and execution for body shop manufacturing systems.
• Serve as the technical authority for PLC, robotics, and network architecture standards.
• Manage and execute complex electrical and controls projects including new installations, major upgrades, model change activities, throughput improvements, and lifecycle replacements.
• Develop and approve cost estimates, investment forecasts, business cases, and appropriation requests for capital projects.
• Provide technical mentorship to Controls Engineers, Automation Engineers, and Skilled Trades across multiple shifts.
• Lead root cause analysis and resolution of complex equipment and system failures.
• Drive continuous improvement initiatives utilizing statistical methods and data-driven decision making.
• Coordinate with Manufacturing Engineering, corporate engineering organizations, and suppliers on new model planning, CQPI, sourcing, and equipment validation.
• Establish and manage project support plans between plant operations, corporate engineering, and contractor resources.
• Represent Engineering in plant leadership meetings and cross-functional business planning activities.
• Influence plant-wide goals through Business Plan Deployment and cross-functional alignment.
• Support implementation of Global Manufacturing Systems and Quality Network initiatives to improve operational excellence.
• Oversee development and adherence to engineering standards, documentation, and best practices.
• Develop and monitor project schedules, risk mitigation plans, and execution timelines.
• Provide input into plant capital planning and Central Manufacturing Engineering budgets.
• Ensure long-term reliability, maintainability, and cost efficiency of manufacturing equipment and infrastructure.
• Drive energy efficiency, operational cost reduction, and maximum throughput strategies.
• Partner with Plant Training teams to develop and deploy training for new technologies introduced to the facility.
• Champion safety as the highest priority, enforcing safe work practices and driving improvements in ergonomics, health, safety, and housekeeping.
• Maintain strong working relationships with hourly employees, union leadership, plant management, suppliers, and external support organizations.

Skills

Rockwell/Allen-Bradley PLC

FANUC robotics

Welding systems

Electrical schematics

Industrial networks

Safety-rated controls

Root cause analysis

Data-driven decision making

Leadership

Education

Bachelor’s degree in Electrical Engineering or Mechatronics

Tools

MES

SCADA

Data acquisition

Job description

Job Description This is a 2nd shift opportunity This job may be eligible for relocation benefits GM DOES NOT PROVIDE IMMIGRATION-RELATED SPONSORSHIP FOR THIS ROLE. DO NOT APPLY FOR THIS ROLE IF YOU WILL NEED GM IMMIGRATION SPONSORSHIP (e.g., H-1B, TN, STEM OPT, etc.) NOW OR IN THE FUTURE. Onsite: This role is categorized as onsite. This means the successful candidate is expected to report to Orion, MI on a full-time basis.

What You’ll Do

• Lead controls engineering strategy and execution for body shop manufacturing systems
• Serve as the technical authority for PLC, robotics, and network architecture standards.
• Manage and execute complex electrical and controls projects including new installations, major upgrades, model change activities, throughput improvements, and lifecycle replacements.
• Develop and approve cost estimates, investment forecasts, business cases, and appropriation requests for capital projects.
• Provide technical mentorship to Controls Engineers, Automation Engineers, and Skilled Trades across multiple shifts.
• Lead root cause analysis and resolution of complex equipment and system failures.
• Drive continuous improvement initiatives utilizing statistical methods and data-driven decision making.
• Coordinate with Manufacturing Engineering, corporate engineering organizations, and suppliers on new model planning, CQPI, sourcing, and equipment validation.
• Establish and manage project support plans between plant operations, corporate engineering, and contractor resources.
• Represent Engineering in plant leadership meetings and cross-functional business planning activities.
• Influence plant-wide goals through Business Plan Deployment and cross-functional alignment.
• Support implementation of Global Manufacturing Systems and Quality Network initiatives to improve operational excellence.
• Oversee development and adherence to engineering standards, documentation, and best practices.
• Develop and monitor project schedules, risk mitigation plans, and execution timelines.
• Provide input into plant capital planning and Central Manufacturing Engineering budgets.
• Ensure long-term reliability, maintainability, and cost efficiency of manufacturing equipment and infrastructure.
• Drive energy efficiency, operational cost reduction, and maximum throughput strategies.
• Partner with Plant Training teams to develop and deploy training for new technologies introduced to the facility.
• Champion safety as the highest priority, enforcing safe work practices and driving improvements in ergonomics, health, safety, and housekeeping.
• Maintain strong working relationships with hourly employees, union leadership, plant management, suppliers, and external support organizations.

Your Skills and Abilities (Required Qualifications)

• Advanced ability to program, troubleshoot, and optimize Rockwell/Allen-Bradley ControlLogix PLC systems in high-volume automotive manufacturing environments.
• Advanced troubleshooting and programming experience with FANUC robotic systems, including robot path recovery, fault diagnostics, and production optimization.
• Strong understanding of welding systems, weld controllers, weld schedules, and robotic welding applications?
• Expert ability to read, interpret, and modify electrical schematic and controls documentation.
• Advanced troubleshooting experience with automated body shop manufacturing systems, material handling equipment, and conveyor controls.
• Strong knowledge of industrial communication networks including Ethernet/IP, DeviceNet, ControlNet, and integrated robot-to-PLC communication.
• Experience supporting safety-rated control systems, robot safety zones, interlocks, and machine safeguarding requirements.
• Strong analytical and structured problem-solving capabilities utilizing root cause analysis and data-driven methodologies.
• Effective leadership, communication, and interpersonal skills with the ability to influence cross-functional teams.
• Willingness to work 2nd shift
• Willingness to support weekend or extended hours during critical production and project phases.

Preferred Qualifications

• Five or more years of experience in automotive body shop, welding, or assembly manufacturing operations.
• Experience supporting robotic welding cells, framing systems, underbody/body-side lines, or final body assembly processes.
• Experience leading automation strategies, major equipment installations, or large capital projects in a body shop environment.
• Bachelor’s degree in Electrical Engineering, Mechatronics Engineering, or equivalent technical experience.
• Experience with manufacturing systems integration including (MES, SCADA, data acquisition)
• Knowledge of dimensional quality systems, automated measurement technologies, and body build quality requirements.
• Demonstrated experience leading, mentoring, or supervising engineering and technical teams.
• Experience supporting new vehicle launches, tooling integration, and production ramp-up activities.

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