Automation Controls Engineer

About the role

The Automation Controls Engineer is a plant-embedded, hands-on engineering role supporting the General Assembly manufacturing operations during off-shift hours. This position is often the only controls engineer on shift and requires strong independent technical judgment to troubleshoot, stabilize, and improve production equipment with limited escalation support.

Responsibilities

• Provide hands-on troubleshooting and support for PLC-, drive-, and network-based manufacturing systems during 3rd-shift production.
• Serve as the primary controls engineering escalation point for Skilled Trades during off-shift events.
• Diagnose and resolve issues on automotive conveyance systems (e.g., skid, skillet, power-and-free, EMS/VAC).
• Support and troubleshoot general assembly equipment.
• Troubleshoot and support Rockwell PowerFlex VFDs, motor starters, and related drive-controlled equipment impacting throughput or process stability.
• Support, troubleshoot, and modify Siemens HMIs programmed via TIA Portal, including alarm handling, visualization, and operator interface issues.
• Support and stabilize PID-controlled processes, including temperature, airflow, pressure, and flow loops, in coordination with operations.
• Make sound risk-based decisions during live production regarding intervention, containment, or deferral to dayshift.
• Support and execute controls projects during planned shutdowns, downtimes, and model launch activities, including installation support, integration, debug, and validation.
• Collaborate with Manufacturing Engineering, Maintenance, and Skilled Trades to improve equipment reliability, process stability, and maintainability.
• Maintain and update controls documentation, backups, and standards as required.
• Champion safety as the highest priority during all troubleshooting and project activities.

Qualifications

• 3+ years of experience as an automation controls engineer, robotics engineer, manufacturing engineer, or robot programmer.
• Strong technical knowledge and troubleshooting experience with robotics and automation systems in a manufacturing environment.
• Hands-on experience with Fanuc 2D and 3D vision sensors.
• Ability to program, troubleshoot, and modify Rockwell / Allen-Bradley ControlLogix or GuardLogix PLCs in a production environment.
• Demonstrated hands-on experience supporting automotive conveyance systems (e.g., skid, skillet, power-and-free, EMS/VAC).
• Strong troubleshooting experience with Rockwell PowerFlex VFDs and motor starters.
• Working knowledge of PID control fundamentals and experience stabilizing temperature, airflow, pressure, or flow processes.
• Working knowledge of DeviceNet and EtherNet/IP industrial networks and associated diagnostics.
• Must be able to work off shifts when required.

Preferred Qualifications

• 3+ years of prior automotive or manufacturing experience, particularly in General Assembly manufacturing environments.
• Bachelor’s Degree preferred in an engineering discipline.
• Experience serving as the primary or sole controls engineer on an off-shift.
• Experience supporting or commissioning large-scale conveyance systems.
• Working knowledge of GM controls standards (e.g., GCCH-1, GCCS-2).
• Experience with Fanuc robots or robot-integrated systems.
• EPLAN experience or certification.
• Experience with vision systems (e.g., Cognex, VMT, Liberty Reach, Keyence).