Body Department Controls Engineer

General Motors•Fairfax, VA

4d•Onsite

About The Position

The Body Department Controls Engineer is responsible for the safe, reliable, and efficient operation and improvement of automated body shop systems. This role provides technical leadership for controls, robotics, process automation, plant-floor systems, and equipment integration across the body department. The engineer supports daily production, new product and equipment launches, troubleshooting, system upgrades, and continuous improvement. This position works closely with body operations, skilled trades, maintenance, quality, safety, information technology, manufacturing engineering, suppliers, and contractors to improve safety, quality, delivery, cost, and equipment performance. This is an onsite manufacturing engineering role requiring regular presence in the body department and on the plant floor. The role requires shift rotation, weekends, shutdown, or extended-hours support during launches, critical equipment work, troubleshooting, and planned maintenance activities. Travel to suppliers or other GM locations may be required based on business needs.

Requirements

Bachelor’s degree in electrical, controls, automation, computer, mechanical, manufacturing, or a related engineering discipline, or an Associate’s degree and equivalent relevant experience may be considered.
Experience supporting industrial automation or controls in a manufacturing environment.
Ability to read and interpret electrical schematics, control-panel drawings, equipment specifications, and engineering documentation.
Demonstrated ability to troubleshoot complex automation and equipment problems using data and structured problem-solving methods.
Strong communication, organization, project-management, and collaboration skills.
Ability to manage multiple projects and priorities with autonomy and accountability.
Commitment to safe work practices and continuous improvement.

Nice To Haves

Working knowledge of programmable logic controllers, human-machine interfaces, industrial networks, drives, sensors, safety circuits, robotics, and electrical control systems.
Experience in an automotive manufacturing or body shop environment.
Experience with Rockwell Automation or Siemens controls platforms, industrial Ethernet, Devicenet networks, motion control, and variable-frequency drives.
Experience with Fanuc robotics systems.
Experience with vision systems, Fanuc 2D/3D, Keyence, or Photoneo.
Knowledge of plant-floor production monitoring, routing and tracking, traceability, or manufacturing execution systems.
Experience with equipment commissioning, factory acceptance testing, site acceptance testing, or production launch.
Familiarity with error proofing, data analytics, Power BI, or other automation-support tools.
Knowledge of structured problem solving, lean manufacturing, Six Sigma, failure-mode analysis, process control plans, and change management.

Responsibilities

Analyze, troubleshoot and diagnose automation faults, controls issues, communication problems, equipment alarms, and recurring production interruptions.
Provide engineering support on equipment, automation systems, interface systems and robots using standard engineering software and hardware tools.
Lead or support the design, programming, integration, installation, commissioning, validation, and launch of new or modified body equipment and systems.
Develop and maintain automation requirements, control-panel documentation, electrical drawings, software backups, network documentation, equipment standards, and change records.
Coordinate with suppliers and contractors on controls design, equipment builds, factory testing, site installation, commissioning, and final acceptance.
Improve equipment availability, throughput, first-time quality, process stability, energy performance, and material utilization through data-driven problem solving.
Apply structured problem-solving methods to identify root causes and implement sustainable corrective actions.
Support machine safety, risk-reduction activities, safeguarding, validation, lockout requirements, and compliance with applicable GM safety standards.
Collaborate with maintenance and skilled trades to improve preventive maintenance, troubleshooting methods, spare-parts strategy, and technical training.
Support plant-floor systems and manufacturing data interfaces used for production monitoring, routing, tracking, traceability, and reporting.
Participate in program timing reviews, equipment design reviews, readiness assessments, production trials, and launch activities.
Create, maintain, and improve standardized work, programming practices, troubleshooting guides, and engineering procedures.
Provide technical direction to less-experienced engineers, suppliers, contractors, and plant support personnel as needed.
Communicate project status, technical risks, decisions, and results to plant and engineering leadership.
Support TIP (Throughput Improvement) initiatives as required.
Perform training and mentorship to skilled trades and junior personnel.
Provide a safe environment and comply with all policies.
Support DLA (Device Level Analytics) initiatives, software implementation and system validation.