Controls Engineer

Job Title:
Controls Engineer - Automotive / General Motors Programs
Company:
Gear 5 Automation
Location:
Michigan (with travel to client sites)
Job Type:
Full-Time

Company Overview:

Gear 5 Automation
is a leading provider of automation and engineering solutions for the automotive industry. We pride ourselves on delivering cutting-edge technology and robust systems that drive the future of manufacturing. We are a trusted partner to top automotive OEMs, and we are currently seeking a talented Controls Engineer to support our projects with General Motors.

Job Summary:

We are looking for an experienced and self-motivated Controls Engineer to design, develop, program, and commission automation and control systems for automotive manufacturing processes. The ideal candidate will have significant hands-on experience working directly with General Motors (GM) standards, specifications, and plant floor environments. You will be a critical member of our engineering team, ensuring that projects are delivered on time and meet the rigorous quality standards of our clients.

Key Responsibilities:

• Design and develop control systems for automated manufacturing equipment, including robotics, PLCs, HMIs, and vision systems.
• Program Rockwell/Allen-Bradley PLCs (ControlLogix, CompactLogix) using Studio 5000, ensuring strict adherence to GM's Global Common Controls Software (GCCS-2) standards.
• Develop HMI applications using FactoryTalk View Studio (ME/SE) that comply with GM's Global Common Controls HMI (GCCH-1) standards.
• Configure, program, and integrate FANUC robots for various applications (material handling, welding, sealing, etc.).
• Develop and debug control system networks, including Ethernet/IP, DeviceNet, and Safety I/O.
• Lead the on-site commissioning, startup, and validation of control systems at GM manufacturing facilities.
• Troubleshoot and resolve complex electrical, software, and networking issues during project implementation and production support.
• Collaborate with mechanical engineers, project managers, and customer representatives to ensure system functionality and project success.
• Create and maintain all necessary project documentation, including electrical schematics, I/O lists, and program backups.
• Provide training and support to plant maintenance and engineering personnel.

Required Qualifications & Skills:

• 3+ years of direct experience as a Controls Engineer in the automotive manufacturing industry.
• Demonstrated, hands-on experience with General Motors controls standards and specifications (GCCS-2, GCCH-1, etc.). This is a mandatory requirement.
• Proficiency in programming Rockwell/Allen-Bradley PLCs (Studio 5000 / RSLogix 5000).
• Experience developing applications for HMIs (FactoryTalk View).
• Ability to read and interpret electrical and mechanical schematics.
• Strong troubleshooting skills and a logical approach to problem-solving.
• Excellent communication skills and the ability to work effectively within a team.
• Willingness and ability to travel to customer sites (up to 30%, may vary by project).

Preferred Qualifications:

• Experience programming and integrating FANUC robots.
• Familiarity with Siemens (TIA Portal/Step 7) PLCs and HMIs.
• Experience with machine vision systems (Cognex, Keyence).
• Knowledge of automotive manufacturing processes, such as Body-in-White (BIW), General Assembly, or Powertrain.
• Experience with industrial network design and configuration.
• Familiarity with automation simulation software (e.g., Process Simulate, RoboDK).

What We Offer:

• Competitive salary and performance-based bonuses.
• Comprehensive benefits package including medical, dental, and vision insurance.
• Generous paid time off (PTO) and company holidays.
• Opportunities for professional development and career growth.

• A dynamic and collaborative work environment at the forefront of automotive technology.

• Gear 5 Automation
  is an Equal Opportunity Employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.