Controls Automation Engineer

Job 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 Youll 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)

Bachelors 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

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