Controls Automation Engineer

Description
This higher level Automation / Controls Engineer will provide technical leadership for press line controls, automation, and safety systems in a high-volume stamping environment. This role is responsible for maintaining and improving reliability of manufacturing press systems, leading complex troubleshooting, and supporting new equipment integration and upgrades. The engineer partners closely with maintenance, production, safety, and central engineering to ensure safe, stable, and capable operations.
The successful candidate will be hands-on who can balance day-to-day operational support with long-term system upgrades and standardization while driving a strong safety culture.
What You'll Do (Responsibilities):
• Ensure all controls solutions comply with GM Global Workplace Safety standards (e.g., PS4, G-DHS) and applicable regulatory requirements (electrical, machine guarding, LOTO/ESWP).
• Support risk assessments and safety FMEAs for new and existing equipment; implement engineered safeguards and safety-rated controls.
• Champion safe work practices for themselves, trades, and contractors.
• Serve as the primary controls resource for assigned press lines, including legacy and upgraded platforms.
• Diagnose and resolve chronic and emergent issues involving PLCs, HMIs, drives, safety relays, networks, and field devices.
• Develop and maintain robust PLC logic, fault handling, and diagnostics (traps, latches, interlocks) to permanently address recurrent issues.
• Lead or support controls scope for new equipment, major rebuilds, and control system upgrades (hardware/software migration, network re-architecture, HMI redesign).
• Collaborate with corporate engineering and vendors on system architecture, standards, and commissioning plans.
• Support run-at-rate, capability validation, and handoff to operations for new or modified systems.
• Act as key technical liaison between the plant, equipment OEMs, and headquarters engineering for controls-related issues, upgrades, and warranty work.
• Prepare clear problem statements, data, and troubleshooting records to drive effective vendor root-cause analysis and corrective actions.
• Challenge and validate vendor solutions; ensure long-term maintainability and alignment with GM standards.
• Provide skilled trades support for complex breakdowns; on a limited basis to include phone support, weekends, call-ins, etc.
• Coach, mentor, and train electricians, technicians, and junior engineers on press operations, troubleshooting methods, and safe work practices.
• Use GM systems and plant tools (e.g., TIP, downtime tracking, problem-solving databases) to document issues, drive root-cause analysis, and close actions.
• Analyze downtime, scrap, and quality data to identify trends and prioritize controls-related improvements.
• Support formal problem-solving processes (e.g., PPS, PFMEA updates, corrective actions) for controls-related issues.
• Maintain up-to-date controls documentation (electrical schematics, I/O lists, network diagrams, software backups, change logs).
• Contribute to development and enforcement of plant controls standards (naming conventions, HMI look/feel, safety design, PS4 conformance).
• Proactively identify and execute continuous improvement opportunities to reduce unplanned downtime, improve maintainability, and mitigate obsolescence (e.g., HMI replacements, standardized hardware, spares strategies).
• Demonstrate ownership of press performance and act with urgency to support production needs while balancing long-term system health.
• Support development of interns and early-career engineers through mentoring, coaching, and project assignments.
• Model GM behaviors and values, including commitment to customers, integrity, and collaboration across departments.
Your Skills and Abilities (Required Qualifications) -
• Bachelor's degree in Electrical Engineering, Controls/Automation Engineering, Computer Engineering, or related technical field; or equivalent experience.
• 3+ years of experience in controls/automation engineering in a manufacturing environment (stamping, assembly, machining, body shop, paint, or similar heavy industrial preferred).
• Strong proficiency with major PLC/HMI platforms (e.g., Rockwell ControlLogix/Studio 5000, Siemens, or equivalent) and industrial networks (EtherNet/IP, Profinet, etc.).
• Working knowledge of machine safety (safety PLCs, interlocks, light curtains, safety relays, risk assessment, safe stop, lockout/tagout concepts).
• Proven debugging and problem-solving skills under time pressure in a production environment.
• Effective communication skills to interface with skilled trades, production, engineering, vendors, and leadership.
• Demonstrated ability to prioritize and manage multiple projects in a fast-paced, production-critical environment.
What Can Give You a Competitive Edge (Preferred Qualifications):
• 5+ years of Experience with stamping press controls, transfer/blanking lines, and associated automation (coil feed, transfer, destack, end-of-line, etc.).
• Experience supporting major press upgrades, rebuilds, or new press installations, including commissioning and run-at-rate.
• Appropriate interpersonal styles and communication methods to work effectively with business partners to meet mutual goals
• Experience in automotive or high-volume metal/assembly manufacturing.
• Experience with industrial vision systems, robots, motion control, or servo applications used in press operations.
• Experience leading capital projects from concept through commissioning and handover.
• Demonstrated leadership in cross-functional problem solving, project execution, and coaching/mentoring others.
• Availability for off-shift, weekend, and call-in support during major breakdowns, launches, and critical activities.
• Primarily plant-floor-based role supporting three-shift stamping operations; require presence on the floor around operating presses and associated equipment
GM does not provide immigration-related sponsorship for this role. Do not apply for this role if you will need GM immigration sponsorship now or in the future. This includes direct company sponsorship, entry of GM as the immigration employer of record on a government form, and any work authorization requiring a written submission or other immigration support from the company (e.g., H1-B, OPT, STEM OPT, CPT, TN, J-1, etc.)
This role is categorized as onsite. This means the selected candidate is expected to report to a specific location on a full-time basis.
This job may be eligible for relocation benefits.
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