Senior Controls Engineer – PLC Automation & FANUC Robotics
Location: On-site | GM Flint Engine Manufacturing Facility
Job Type: Long-Term Contract (Approximately 12 Months, Potential Extension)
Shift: 2nd Shift | Monday–Friday, 2:00 PM–10:30 PM
Schedule: Weekend work and overtime required
Hourly Rate: $60-65/hr
Position Overview
We are seeking an experienced Senior Controls Engineer to support automated manufacturing equipment and production operations within a high-volume automotive engine manufacturing facility.
This position will focus on troubleshooting, maintaining, and improving industrial control systems supporting V8 engine block and cylinder head machining operations. The Controls Engineer will work directly with production and maintenance teams to diagnose equipment failures, resolve automation issues, and minimize manufacturing downtime.
The ideal candidate will have extensive hands-on experience with GM Global Common Controls Software/Hardware (GCCS/GCCH), Rockwell and Siemens PLCs, Siemens TIA Portal, and FANUC robotics with iRVision.
This is a highly technical, hands-on position requiring an engineer who can independently troubleshoot complex manufacturing equipment with minimal foundational training.
Key Responsibilities
- Provide hands-on controls engineering support for automated machining equipment and manufacturing production systems.
- Troubleshoot PLC-controlled machinery, industrial automation systems, and production equipment to identify and resolve operational issues.
- Diagnose, modify, and troubleshoot PLC logic to restore equipment functionality and minimize production downtime.
- Support GM Global Common Controls Software and Hardware (GCCS/GCCH) systems.
- Program, troubleshoot, and maintain Rockwell PLCs and Siemens Step 7 PLCs.
- Utilize Siemens TIA Portal Versions 17 and 18 to support PLC programming, diagnostics, and troubleshooting.
- Troubleshoot and support Siemens Human Machine Interface (HMI) systems.
- Diagnose and resolve issues involving FANUC industrial robots and integrated iRVision systems.
- Collaborate with maintenance technicians, production personnel, and fellow controls engineers to resolve complex equipment issues.
- Support the design, modification, and troubleshooting of electrical control panels, wiring diagrams, and machine control systems.
- Troubleshoot servo drives, machine control hardware, and associated automation software.
- Perform control system testing, debugging, commissioning, and equipment startup support as needed.
- Review electrical schematics and technical documentation to identify equipment faults and implement corrective actions.
- Identify opportunities to improve equipment reliability, reduce recurring failures, and increase production efficiency.
- Provide technical guidance and training to maintenance and production personnel.
- Ensure controls engineering activities comply with applicable electrical, machine safety, and manufacturing standards.
Required Qualifications
- Extensive hands-on experience supporting industrial controls and automated manufacturing equipment.
- Strong working knowledge of PLC programming, logic interpretation, troubleshooting, and diagnostics.
- Experience with Rockwell PLCs and Siemens Step 7 PLC systems.
- Proficiency with Siemens TIA Portal and Siemens HMI systems.
- Experience troubleshooting FANUC industrial robots and integrated vision systems, including iRVision.
- Ability to troubleshoot complex automation equipment independently in an active production environment.
- Strong understanding of electrical control systems, industrial automation hardware, and machine troubleshooting.
- Ability to read and interpret electrical schematics, wiring diagrams, and control system documentation.
- Strong analytical, troubleshooting, and problem-solving skills.
- Ability to communicate effectively and collaborate with production, maintenance, and engineering personnel.
- Willingness to work second shift, overtime, and scheduled weekends as production needs require.
Preferred Qualifications
- 8–10 years of relevant controls engineering, industrial automation, or manufacturing technology experience.
- Bachelor's degree in Electrical Engineering, Controls Engineering, Automation Engineering, or a related technical discipline. Equivalent practical experience will be considered.
- Experience with GM Global Common Controls Software and Hardware (GCCS/GCCH).
- Experience supporting automotive powertrain manufacturing, engine machining, or similar high-volume automated manufacturing operations.
- Experience with Siemens TIA Portal Versions 17 and 18.
- Proficiency with AutoCAD and electrical control system design.
- Experience with servo drive hardware and software.
- Familiarity with pneumatic and hydraulic control systems.
- Knowledge of industrial electrical and machine safety standards.
- Experience providing technical leadership or guidance to maintenance and engineering teams.
Work Environment & Schedule
- Location: Fully on-site at an automotive engine manufacturing facility.
- Primary Shift: Monday–Friday, 2:00 PM–10:30 PM.
- Weekend Requirements: Typically two Saturdays worked followed by one Saturday off. Sunday work may occasionally be required based on production demands.
- Overtime: Approximately 8 hours of overtime anticipated, subject to production needs.
- Schedule Flexibility: Management rotates weekend coverage across the engineering team and aims to provide at least one day off per week.
- Travel: No routine travel required.
- Contract Duration: Approximately 12 months, with potential for extension.
- Growth Opportunity: Potential consideration for direct employment based on performance, business needs, and position availability.
Why Consider This Opportunity?
This position offers an opportunity to work directly with advanced industrial automation and robotic manufacturing systems in a major automotive production environment.
You will join an established second-shift controls engineering team supporting active manufacturing operations, gain exposure to a broad range of PLC and robotic technologies, and play a critical role in maintaining equipment reliability and production efficiency.
For an experienced Controls Engineer who enjoys hands-on troubleshooting, complex automation challenges, and working directly with manufacturing equipment, this role offers a technically engaging environment with potential long-term opportunities.