Senior Manufacturing Process Controls Engineer

General Motors LLC; Spring Hill (TN); On-site; USD 120,000 - 170,000; Full time

Job summary

General Motors LLC is seeking an experienced Automation Controls Engineer to plan, execute and launch high-volume automation for traditional and electric vehicle manufacturing. You will collaborate with GM engineering teams, suppliers, and system integrators to ensure timely runoff, design reviews and safety-compliant execution.

You will design, validate and optimize control architectures, including PLC, CNC, HMIs, and robotics, while maintaining alignment with global standards and project

Qualifications

• Bachelor's degree in Electrical Engineering or related field with strong automation focus.
• Five years of progressive experience in automotive/industrial automation controls.
• Experience with PLCs, CNCs, HMI/SCADA, and safety standards.

Responsibilities

• Plan, execute, and launch high volume automation for ICE and BEV production lines.
• Engage with GM engineering, suppliers, and integrators to runoffs and design reviews.
• Validate controls, implement safety standards, and support program timing.
• Develop and validate HMI screens and PLC programs across plants

Skills

Siemens Step7

SINUMERIK 840D CNC

Rockwell PLC

HMI/SCADA

TIA Portal

Education

Bachelor's degree in Electrical Engineering

Tools

E-plan P8

Electrical AutoCAD

Studio5000

WinCC Flex

Job description

DUTIES

Plan, execute, and launch high volume conventional ICE passenger vehicle transmission and Battery Electric Vehicle (BEV) Rechargeable Energy Storage Systems (RESS), fuel cells, and Automated storage retrieval systems (ASRS), Ultium battery cells and components, electrification for GM Global Propulsion Systems (GPS) for U.S., Canada and Mexico Transmission and Electric Drive Unit (DU) plants. Maintain active engagement and relationship on daily basis with suppliers, integrators of machinery, tooling, hardware and software and GMNA Region (U.S., Canada and Mexico) engineering departments at headquarters and in GM plants for carrying out runoff activities, design reviews, perform functional validations to meet program launch timing, incorporate General Motors Flexible Assembly Control Systems (FACS), Global Common Controls Hardware standard (GCCH-1) and Global Common Controls Hardware software (GCCS-1), Fanuc robotics Global 4 standards, Flexible assembly controls systems (FACS) vision and third party controller Interfaces during different phases of program execution. Engineer, design, evaluate, implement, and optimize current and new automation controls techniques for industrial machining equipment, cutting tools, error proofing systems, and plant floor networks, ancillary equipment (load/unload tooling, washers, special purpose machines), robotics, material handling, parts sorting, conveyors, automated guided vehicles (AGVs), heat treat and, leak test machines, third party manufacturing process equipment, and automation controls technologies including high end 840D Computer Numerically Controlled (CNCs), Programmable Logic Controllers (PLCs), Human Machine Interfaces (HMIs), Siemens Step 7, TIA Portal, Studio5000, Design Studio. Design hardware and switchgears sizing, support build integration, prepare review electrical drawings and schematics including low voltage switchgears according to International Electrotechnical Commission (IEC) 947 norms and AC/DC power circuits, per Global Machinery industrial Electrical Standard SP-E-60204 and IEC 62061 Safety of Machinery, and electrical UL 508A, NFPA 70E and create Bill of Material (BOM) reports using software tools E-plan P8 and Electrical AutoCAD. Industrial communication protocols Interface Ethernet IP/Profinet/Profibus networks and GM’s IT Powertrain and Global Production and monitoring controls PTPMC, GPMC, Software Program debug, interface, validation, and controls troubleshooting third party devices such as Press, laser and vision systems, Process data monitoring system, RFID, Printers, 3D barcode scanners etc. Engage with GM global equipment design and buyoff process as controls expert providing technical directions to execute major program launches, integrate build schema and collaborating with OEM suppliers, integrators and safety expert teams during g-Comply safety buyoff process, g- Risk assessments, simultaneous engineering, process error proofing, checklist and safety controls system validation according to Global Design for Health and Safety Specification (GHS- 1) risk management and process; and Programmable Safety System (PSS) guidelines in accordance with GM’s global Monitored Power Systems (MPS), Safety Controls Systems (SCS) failsafe design standards. Automate Fanuc robotics to prove automotive applications, load teach part programs, validating robot process paths, Dual Check Safety (DCS) zones, payload, Mastering, and Vision applications 3D IR (infrared) using GM approved Kowa, Matrox and Cognex cameras hardware per GVS requirements, auto backup program methods, develop Human Machine Interface (HMI) screens enabling test sequence of operations, program recovery and faults. 20% domestic travel required.

REQUIREMENTS

Bachelor's degree in Electrical Engineering, Mechanical Engineering, or related field of study and Five (5) years of Progressive, post-baccalaureate experience in a related occupation. Four (4) years of experience with: Siemens Step7 Simatic Manager PLC, SINUMERIK 840D CNC hardware and software PLC and NC programming with safety integrated knowledge, Sinamics VFD and Servo Drives; HMI/SCADA, TIA Portal, WinCC Flex, Starter/Drive ES, CNC Technology, Advanced HMI, toolbox, HMI Pro and Rockwell PLC controllers; RSLogix5000, Design studio, Hardware Design using E-plan, Auto-cad; General Motors Global Common Controls Architecture, Specifications and Standards (GCCS, GCCH) for PLC and G4 Robots, Flexible Assembly Control Systems (FACS) and design, PTPMC, GPMC; Industrial Automation Controls Protocols like Profinet, Profibus, Ethernet and Interfacing with third party specialty devices like Press systems, Nutrunners, Cameras, RFID, laser systems; Process system design development, implementation and testing along with technical problem resolution, root cause analysis and mange key strategic interfaces within vehicle/powertrain automotive system using standard methodologies; Simultaneous engineering activities and equipment reuse, process error proofing including controller safety G risk with cross functional groups; and Supporting Controls run off, approving electrical drawings, and continuously improving quality, cost, system responsiveness and safety. #LI-DNI

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