Senior Error Proofing Controls Engineer
General Motors•Warren, MI
•Onsite
About The Position
General Motors is seeking a Senior Error Proofing Engineer to develop, implement, validate, and improve manufacturing error-proofing systems that prevent mis-builds and protect customer quality. This role translates PFMEA- and DFMEA-driven requirements into practical plant-floor solutions and works cross-functionally to support launch readiness and sustained production performance.
Requirements
- Bachelor's degree in Electrical Engineering, Controls Engineering, Manufacturing Engineering, Industrial Engineering, or a related technical field
- 7+ years of manufacturing experience, including 3+ years of hands-on error-proofing implementation and launch experience in automotive or high-volume production
- Experience with error-proofing systems such as EPP, SEP, and FAC
- Strong automation and controls background, including PLCs, HMI development, controls hardware integration, and field troubleshooting
- Working knowledge of machine vision, barcode and DPM verification, scanners, sensors, pick-to-light, tethering, torque and tool interlocks, and attribute gages
- Experience with PFMEA, DFMEA alignment, SOR creation, validation planning, and production launch support
- Strong cross-functional collaboration, troubleshooting, project management, and communication skills
Nice To Haves
- Experience with GSIP relationship mapping, tool-event configuration, or similar error-proofing traceability systems
- Experience launching error-proofing systems across GM plants or vehicle and GPS programs
Responsibilities
- Lead error-proofing strategy for manufacturing processes to prevent mis-builds
- Translate PFMEA and DFMEA outputs into error-proofing requirements, failure-mode coverage, and detection criteria
- Partner with Vision, Controls, Product Engineering, Quality, Manufacturing, GM plants, and integrators to deploy solutions
- Support SOR development, design reviews, equipment alignment, and plant-floor implementation
- Verify pass/fail logic, challenge parts, scanners, vision systems, and attribute gages perform as intended
- Maintain plant error-proofing master lists and support validation, verification, bypass controls, and reaction plans
- Support launch execution and continuous improvement of scanner, barcode, vision, gripper-engagement, and style-selection logic
- Coach junior engineers on implementation, validation, troubleshooting, and launch support
Benefits
- Relocation benefits
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What This Job Offers
Job Type
Full-time
Career Level
Senior
