Senior Error Proofing Controls Engineer

General Motors; Warren (MI); On-site; USD 110,000 - 160,000; Full time

Job summary

General Motors seeks a Senior Error Proofing Engineer to develop, implement, validate, and improve manufacturing error-proofing systems that prevent mis-builds and protect customer quality.

Responsible for translating PFMEA/DFMEA outputs into practical plant-floor solutions, collaborating across Vision, Controls, Product Engineering, Quality, and Manufacturing to ensure launch readiness and sustained performance.

Qualifications

• Bachelor's degree in Electrical Engineering, Controls Engineering, Manufacturing Engineering, Industrial Engineering, or a related technical field
• 7+ years of manufacturing experience, including 3+ years of hands-on error-proofing implementation and launch experience in automotive or high-volume production
• Experience with error-proofing systems such as EPP, SEP, and FAC
• Strong automation and controls background, including PLCs, HMI development, controls hardware integration, and field troubleshooting
• Working knowledge of machine vision, barcode and DPM verification, scanners, sensors, pick-to-light, tethering, torque and tool interlocks, and attribute gages
• Experience with PFMEA, DFMEA alignment, SOR creation, validation planning, and production launch support
• Strong cross-functional collaboration, troubleshooting, project management, and communication skills

Responsibilities

• Lead error-proofing strategy for manufacturing processes to prevent mis-builds
• Translate PFMEA and DFMEA outputs into error-proofing requirements, failure-mode coverage, and detection criteria
• Partner with Vision, Controls, Product Engineering, Quality, Manufacturing, GM plants, and integrators to deploy solutions
• Support SOR development, design reviews, equipment alignment, and plant-floor implementation
• Verify pass/fail logic, challenge parts, scanners, vision systems, and attribute gages perform as intended
• Maintain plant error-proofing master lists and support validation, verification, bypass controls, and reaction plans
• Support launch execution and continuous improvement of scanner, barcode, vision, gripper-engagement, and style-selection logic
• Coach junior engineers on implementation, validation, troubleshooting, and launch support

Skills

Error-proofing

Cross-functional collaboration

PFMEA/DFMEA

Automation & controls

Machine vision & sensors

Project management

Troubleshooting

Education

Bachelor's degree in Electrical/Controls/Manufacturing/Industrial Engineering or related

Tools

PLCs

HMI development

Vision systems

Scanners & sensors

Job description

General Motors is seeking a Senior Error Proofing Engineer to develop, implement, validate, and improve manufacturing error-proofing systems that prevent mis-builds and protect customer quality. This role translates PFMEA- and DFMEA-driven requirements into practical plant-floor solutions and works cross-functionally to support launch readiness and sustained production performance.

What You'll Do

• Lead error-proofing strategy for manufacturing processes to prevent mis-builds

• Translate PFMEA and DFMEA outputs into error-proofing requirements, failure-mode coverage, and detection criteria

• Partner with Vision, Controls, Product Engineering, Quality, Manufacturing, GM plants, and integrators to deploy solutions

• Support SOR development, design reviews, equipment alignment, and plant-floor implementation

• Verify pass/fail logic, challenge parts, scanners, vision systems, and attribute gages perform as intended

• Maintain plant error-proofing master lists and support validation, verification, bypass controls, and reaction plans

• Support launch execution and continuous improvement of scanner, barcode, vision, gripper-engagement, and style-selection logic

• Coach junior engineers on implementation, validation, troubleshooting, and launch support

Required Qualifications

• Bachelor's degree in Electrical Engineering, Controls Engineering, Manufacturing Engineering, Industrial Engineering, or a related technical field

• 7+ years of manufacturing experience, including 3+ years of hands-on error-proofing implementation and launch experience in automotive or high-volume production

• Experience with error-proofing systems such as EPP, SEP, and FAC

• Strong automation and controls background, including PLCs, HMI development, controls hardware integration, and field troubleshooting

• Working knowledge of machine vision, barcode and DPM verification, scanners, sensors, pick-to-light, tethering, torque and tool interlocks, and attribute gages

• Experience with PFMEA, DFMEA alignment, SOR creation, validation planning, and production launch support

• Strong cross-functional collaboration, troubleshooting, project management, and communication skills

Preferred Qualifications

• Experience with GSIP relationship mapping, tool-event configuration, or similar error-proofing traceability systems

• Experience launching error-proofing systems across GM plants or vehicle and GPS programs