Senior Manufacturing Controls Engineer

General Motors; Warren (MI); Hybrid; USD 110,000 - 170,000; Full time

Job summary

General Motors in Warren, MI, is seeking a Senior Manufacturing Controls Engineer to design, develop, and deploy automated manufacturing systems across GM's production operations. You will lead controls initiatives from concept through production launch and provide technical direction to cross‑functional teams.

The role requires strong experience with PLCs, HMIs, drives, safety systems, and industrial networks, plus ability to travel 25–50% and collaborate with suppliers, IT, and plant personnel

Qualifications

• Bachelor's degree in Electrical/Controls/Computer Engineering or related field.
• 5+ years of experience in manufacturing controls or automation.
• Experience designing, programming, integrating, and commissioning automated manufacturing equipment.
• Strong experience with PLCs, HMIs, drives, safety controls, industrial networks and electrical control systems.
• Ability to read electrical schematics, panel layouts, mechanical drawings, and equipment specs.
• Experience collaborating with cross-functional teams and managing suppliers.

Responsibilities

• Lead controls engineering execution for new and existing manufacturing programs from concept through production launch.
• Develop, review, and approve hardware and software designs including PLCs, HMIs, drives, safety systems, and networks.
• Program, troubleshoot, integrate, and validate automated equipment and production systems.
• Apply GM Global Common Controls standards for hardware, software, build, safety, networks, and cybersecurity.
• Provide technical direction to controls engineers, suppliers, integrators, and plant personnel.
• Manage project scope, timing, risks, issues, deliverables, and escalations through resolution.
• Collaborate with equipment suppliers to establish requirements, review designs, and ensure GM standards.
• Support plant launches, ramp-up, downtime recovery, and complex controls troubleshooting.
• Conduct root-cause analysis and implement corrective actions to improve safety, quality, delivery, cost, uptime, and throughput.
• Develop and maintain standardized controls templates, tools, and documentation.

Skills

Analytical thinking

Cross-functional leadership

Communication

Organizational skills

Decision making

Reading electrical schematics

Education

Bachelor's degree in Electrical/Controls/Computer Engineering

Master’s degree (preferred)

Tools

PLCs & HMIs

Drives & safety systems

Industrial networks

Electrical control systems

Siemens controls

Job description

Senior Manufacturing Controls Engineer

Job Description The Senior Manufacturing Controls Engineer designs, develops, integrates, commissions, launches, and continuously improves automated manufacturing systems supporting GM’s global vehicle and propulsion manufacturing operations. This role provides technical leadership across new product programs, plant launches, equipment upgrades, and production support activities. The engineer collaborates with manufacturing engineering, plant operations, suppliers, product engineering, IT, robotics, safety, cybersecurity, and Global Automation teams to deliver safe, reliable, standardized, and high-performing controls solutions.

What You’ll Do

• Lead controls engineering execution for new and existing manufacturing programs from concept through production launch.
• Develop, review, and approve controls hardware and software designs, including PLCs, HMIs, drives, safety systems, I/O, industrial networks, and plant‑floor interfaces.
• Program, troubleshoot, integrate, and validate automated equipment and production systems.
• Apply GM Global Common Controls standards for hardware, software, build, safety, networks, and cybersecurity.
• Perform or oversee emulation, offline testing, supplier buyoffs, equipment runoffs, installation, commissioning, and production validation.
• Provide technical direction to controls engineers, suppliers, integrators, and plant personnel.
• Manage project scope, timing, risks, issues, deliverables, and escalations through resolution.
• Partner with equipment suppliers to establish requirements, review designs, resolve technical issues, and ensure compliance with GM standards.
• Support plant launches, production ramp‑up, equipment modifications, downtime recovery, and complex controls troubleshooting.
• Conduct root‑cause analysis and implement corrective actions that improve safety, quality, delivery, cost, uptime, and throughput.
• Participate in investment studies, preliminary designs, equipment selection, cost estimating, and technical sourcing activities.
• Develop and maintain standardized controls templates, engineering tools, design aids, and technical documentation.
• Capture lessons learned and incorporate improvements into standards, processes, and future program designs.
• Collaborate with global teams on technology development, proof‑of‑concept activities, and deployment of advanced automation solutions.
• Promote a culture of safety, inclusion, accountability, continuous improvement, and technical excellence.

Required Qualifications

• Bachelor’s degree in Electrical Engineering, Controls Engineering, Computer Engineering, or a related technical field.
• Five or more years of experience in manufacturing controls, automation, electrical engineering, or a related technical discipline.
• Experience designing, programming, integrating, and commissioning automated manufacturing equipment.
• Strong experience with PLCs, HMIs, drives, safety controls, industrial networks, and electrical control systems.
• Ability to read and interpret electrical schematics, panel layouts, mechanical drawings, and equipment specifications.
• Demonstrated experience executing projects and managing equipment suppliers.
• Strong analytical, problem‑solving, communication, organizational, and decision‑making skills.
• Ability to work independently and lead cross‑functional teams in technical center, supplier, and plant environments.
• Willingness to travel domestically and internationally, including occasional extended assignments and off‑shift or weekend support during launches.

Preferred Qualifications

• Master’s degree in Engineering or a related technical field.
• Experience in automotive manufacturing, including vehicle assembly, body, paint, stamping, general assembly, propulsion, battery, or conveyor systems.
• Knowledge of GM Global Common Controls standards for hardware, software, build, safety, networks, or cybersecurity.
• Experience with emulation and virtual validation tools, such as Emulate3D.
• Experience integrating controls with plant‑floor systems, MES, production monitoring, error proofing, Andon, vehicle tracking, or enterprise IT systems.
• Experience with Siemens controls, HMI platforms, EPLAN, machine vision, robotics, or industrial cybersecurity.
• Experience developing automation standards, reusable templates, engineering tools, or technical training.
• Familiarity with scripting or programming languages such as Python, C#, VBA, JavaScript, or XML.
• Experience with lean manufacturing, Six Sigma, and structured problem‑solving methodologies.

Location, Hybrid and Travel

This role is categorized as hybrid. This means the selected candidate is expected to report to a specific location at least 3 times a week {or other frequency dictated by their manager}. The selected candidate will be required to travel on a regular basis (25-50%) for this role. This job may be eligible for relocation benefits. This position requires the ability to legally operate a motor vehicle on a regular basis. A company vehicle will only be provided for this role by passing the Motor Vehicle Report review.

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