Senior Controls Engineer

Gillig•Livermore, CA

53d•Onsite

About The Position

As the leading transit bus manufacturer in the United States, GILLIG buses play a critical role in the environmental and social initiatives in communities across our nation. GILLIG is on the forefront in the transition to zero-emission vehicles and has an unmatched reputation in the industry for quality, reliability, durability, service, and support. From initial design through final assembly, each GILLIG bus is designed and built in Livermore, CA. The GILLIG Engineering department is responsible for the development, customization, and configuration of GILLIG’s clean technology heavy-duty transit buses. We are committed to developing the most reliable vehicles that connect communities, eliminate congestion, and contribute to a greener environment. Our engineers are engaged in designing, analyzing, testing, launching, and problem solving across a wide range of technical areas. The Controls Team is responsible for the development and integration of advanced control algorithms for critical body functions across all vehicle platforms. Working closely with cross-functional teams, they conduct rigorous testing and validation to ensure these algorithms meet functional requirements, comply with regulatory standards, and contribute to delivering high-quality, reliable transit buses to the market. We are looking for a Senior Controls Engineer who will lead the development of control algorithms for critical body functions across all vehicle platforms. You will be directly involved in developing, testing, and releasing algorithms for various systems, subsystems, and components – including the HMI driver display, passenger doors, ramp, interior lighting, HVAC, vehicle safety systems, LV power distribution, etc. – ensuring that all algorithms meet safety, regulatory, reliability, and performance requirements. You will also lead the creation of advanced vehicle diagnostics and detailed troubleshooting guides to support technicians in resolving bus issues effectively. This is a hands-on, on-site role at our Livermore, CA plant and reports to the Controls Engineering Manager but may also receive directions and guidance from other senior and/or staff engineers.

Requirements

Bachelor's or advanced degree in Engineering
Minimum 5 years of experience in the engineering industry, preferably in automotive, commercial, or heavy-duty vehicle design
Fluent with BOM, documentation control, and revision/version management.
Experience working with major component suppliers, engineering service suppliers, testing suppliers, and product validation engineers
Strong, hands-on experience in troubleshooting, product assembly, prototyping, testing, and validation, both onsite and at remote locations
Expertise with open and closed loop control systems for sensors, actuators, body controllers, and ECUs, including proficiency in CAN-Bus, LIN, and Ethernet communication protocols
Prior development work with ladder logic controls (e.g., Allen-Bradley, Siemens PLC), software development using C/C++, or model-based development (e.g., MATLAB Simulink)
Prior experience with integrating controls systems with low and high voltage automotive hardware, such as DCDC converters, motors, inverters, Li-ion batteries, and high-power chargers
High operating knowledge of industry standards such as FMVSS, NHTSA, DOT, NFPA, SAE, and NEC

Nice To Haves

Experience with configure-to-order products and modular BOM management is a plus
Heavy-duty, transit and/or commercial vehicle experience is a plus

Responsibilities

Create functional requirements for vehicle behavior to ensure compliance with program requirements and standards.
Define communication interfaces and protocols for all vehicle systems, while ensuring communication network loads and traffic remain within design limits
Develop, test, and validate control algorithms to improve both existing and future vehicle capabilities
Participate in DFMEA, FMEA-MSR, hazard, and risk assessments to enhance fault detection and minimize potential failures
Create environments to design, test, and refine electronic control systems prior to their integration on a vehicle
Actively contribute to software-specific design test plans.
Perform hands-on troubleshooting, testing, and validation activities both onsite and in the field.
Collaborate with engineers to bring up prototype vehicles and address issues effectively
Lead the development of advanced vehicle diagnostics and create detailed troubleshooting guides to support efficient issue identification and resolution.
Provide technical input to generate vehicle manuals, ensuring accuracy and completeness
Architect and maintain control development processes, including version control, automated code review, and regression testing
Release software through the Product Lifecycle Management (PLM) system while maintaining traceability throughout the entire bus lifecycle
Lead continuous improvement efforts for control systems to enhance vehicle reliability, performance, and customer satisfaction.
Analyze field data and feedback to identify areas for improvement