Advanced Controls Engineer – Robotics Technology Development

GM•Warren, MI

5d•Onsite

About The Position

The Advanced Controls Engineer within the Robotics Technology Development (RTD) group in the Autonomous Robotics Center (ARC) is a senior individual contributor responsible for architecting, delivering, and scaling advanced controls solutions for next‑generation robotic and automation systems across GM manufacturing. You will combine deep, hands-on controls expertise (PLCs, safety, robotics, networks) with system‑level thinking to design and industrialize fenceless and collaborative automation, high‑performance robotic cells, and standardized controls platforms that can be reused across multiple manufacturing verticals (kitting/sequencing, lift assist, fastening, inspection, material movement). As an advanced controls engineer, you will own significant technical workstreams end‑to‑end, exercise independent judgment on complex topics, and provide technical direction and mentorship to other engineers and partners. You will work closely with R&D, ARC, and Manufacturing Engineering to advance solutions from lab prototypes through pilot-line readiness (MRL 4–6), ensuring that controls architectures, safety strategies, and standards are robust, maintainable, and ready for handoff to production programs.

Requirements

Deep, hands-on controls expertise (PLCs, safety, robotics, networks)
System-level thinking
Experience designing and industrializing fenceless and collaborative automation
Experience with high-performance robotic cells
Experience with standardized controls platforms
Ability to own significant technical workstreams end-to-end
Ability to exercise independent judgment on complex topics
Ability to provide technical direction and mentorship to other engineers and partners
Experience advancing solutions from lab prototypes through pilot-line readiness (MRL 4–6)
Experience with PLC, safety PLC, HMI, and related control logic development and maintenance
Experience architecting and integrating industrial robots (e.g., FANUC, UR) with PLCs, safety systems, and field devices
Experience designing and validating fenceless / collaborative controls strategies
Experience applying GM safety standards and risk‑assessment processes
Experience defining and validating safety functions, interlocks, and safety device integration
Experience contributing to and stewarding controls architecture patterns and standards
Experience driving standardization and reuse of controls building blocks
Experience owning controls workstreams for development cells, pilot systems, and advanced technology projects
Experience partnering with robotics, perception, and software teams to integrate advanced control algorithms, motion planning, vision, and sensing
Experience using simulation, emulation, and virtual commissioning
Experience supporting system bring‑up, debug, and optimization
Experience providing expert support during trials, pilots, and early production runs
Experience collaborating with Manufacturing Engineering, plant teams, IT/OT, and suppliers
Experience providing technical direction and coaching to controls engineers, robotics engineers, and supplier teams
Experience capturing and communicating lessons learned, best practices, and design guidance

Nice To Haves

Experience with Global Common Controls Hardware/Software (GCCH/S)
Experience with GCCS and RTD best practices
Experience with applications such as assembly, material handling, fastening, inspection, and lift assist
Experience with applicable standards and GM practices for fenceless/collaborative controls
Experience with light curtains, scanners, E‑Stops, enabling devices, safety relays/PLCs
Experience with hardware templates, network architectures, software libraries, standardized sequences
Experience with reusable code, test cases, and documentation
Experience with vPLC, robot simulation, digital twins
Experience aligning controls designs with plant standards, cyber requirements, and lifecycle support needs
Experience contributing to ARC/RTD technical roadmaps and standards evolution

Responsibilities

Lead the design, implementation, and commissioning of controls solutions for robotic cells and automation projects within RTD, following GM controls standards and Global Common Controls Hardware/Software (GCCH/S).
Develop and maintain PLC, safety PLC, HMI, and related control logic, including standardized function blocks, diagnostics, and fault‑handling approaches aligned to GCCS and RTD best practices.
Architect and integrate industrial robots (e.g., FANUC, UR) with PLCs, safety systems, and field devices for applications such as assembly, material handling, fastening, inspection, and lift assist, meeting safety, throughput, and quality targets.
Design and validate fenceless / collaborative controls strategies (safety zones, safe speed/position, speed & separation monitoring, power & force limiting) in alignment with applicable standards and GM practices.
Apply GM safety standards and risk‑assessment processes to define and validate safety functions, interlocks, and safety device integration (light curtains, scanners, E‑Stops, enabling devices, safety relays/PLCs).
Contribute to and help steward controls architecture patterns and standards for RTD (hardware templates, network architectures, software libraries, standardized sequences), ensuring they are practical for deployment across plants and suppliers.
Drive standardization and reuse of controls building blocks (templates, reusable code, test cases, documentation) that can be leveraged across ARC verticals and programs.
Own controls workstreams for development cells, pilot systems, and advanced technology projects, from concept and requirements through integration, debug, and pilot-line buyoff (MRL 4–6).
Partner with robotics, perception, and software teams to integrate advanced control algorithms, motion planning, vision, and sensing into production‑representative systems, ensuring they are maintainable by plant organizations.
Use simulation, emulation, and virtual commissioning as appropriate (e.g., vPLC, robot simulation, digital twins) to front‑load debug, validate sequences and safety behavior, and reduce onsite commissioning time.
Support system bring‑up, debug, and optimization at the Global Technical Center and, when required, at manufacturing sites; provide expert support during trials, pilots, and early production runs.
Collaborate with Manufacturing Engineering, plant teams, IT/OT, and suppliers to align controls designs with plant standards, cyber requirements, and lifecycle support needs.
Provide technical direction and coaching to controls engineers, robotics engineers, and supplier teams on RTD standards, safety practices, and advanced controls techniques.
Capture and communicate lessons learned, best practices, and design guidance through documentation, design reviews, and internal forums, contributing to ARC/RTD technical roadmaps and standards evolution.