Controls Engineer

JOB DESCRIPTION

 Develop, modify, troubleshoot, and support PLC and HMI programs for automated manufacturing equipment and production systems.

 Program, configure, and optimize FANUC industrial robots and CRX collaborative robots (CRX30i preferred) for assembly, material handling, inspection, or process automation applications.

 Design, integrate, and validate machine vision systems for inspection, guidance, part verification, and process control.

 Perform sensor, I/O, and safety validation activities including troubleshooting field devices, safety circuits, interlocks, and network communications.

 Support equipment installation, startup, debugging, and commissioning activities at manufacturing facilities.

 Ensure automation systems comply with General Motors automation standards (GCCS/GCCH) and customer specifications.

 Collaborate with manufacturing, controls, quality, and maintenance teams to resolve production issues and improve equipment performance.

 Conduct system testing, FATs, SATs, and production readiness reviews prior to launch.

 Troubleshoot PLC, robot, vision, networking, and electrical issues to minimize downtime and support manufacturing operations.

 Create and maintain controls documentation including electrical schematics, I/O lists, safety validation reports, and operating procedures.

 Support continuous improvement initiatives focused on throughput, quality, reliability, and automation performance.

REQUIRED SKILLS AND EXPERIENCE

Must Haves:

• 3+ years of experience as a Controls Engineer in an automotive or high-volume manufacturing environment.

• Experience supporting General Motors manufacturing facilities or working for an automation company supporting GM standards.

• GCCS/GSSC certification and experience with GCCH (hardware)

• Strong knowledge of GM controls standards, manufacturing processes, and assembly line automation.

• Hands-on experience programming, troubleshooting, and supporting PLC-based automation systems on the plant floor.

• Experience with Siemens Step 7 PLCs and/or Rockwell Allen-Bradley PLCs.

• Familiarity with FACS, EtherNet/IP networking, and industrial communication protocols.

• Experience supporting automation equipment commissioning, debugging, and continuous improvement initiatives in a production environment.

• Experience with Fanuc robots, including troubleshooting and recovering basic robot faults.

• Experience with Cognex and/or Keyence vision systems.

• Strong understanding of industrial networks, robot integration, HMIs, and controls architecture.

• Familiarity with CITI Logic, G-Comply processes, and preparing TIS/SCS electrical tasks.