Senior Manufacturing Process Controls Engineer

General Motors•Spring Hill, TN

About The Position

This role involves planning, executing, and launching high-volume manufacturing processes for various vehicle components including transmission, Battery Electric Vehicle (BEV) Rechargeable Energy Storage Systems (RESS), fuel cells, Automated storage retrieval systems (ASRS), Ultium battery cells, and electrification for GM Global Propulsion Systems (GPS) across North America. The engineer will maintain daily engagement with suppliers, machinery integrators, and GM engineering departments to ensure program launch timing, incorporate specific GM control systems and standards (FACS, GCCH-1, GCCS-1, Fanuc robotics Global 4), and manage third-party controller interfaces. Responsibilities include engineering, designing, evaluating, implementing, and optimizing automation controls for industrial machinery, tooling, error-proofing, plant networks, material handling, robotics, and various specialized manufacturing equipment. This includes working with high-end CNCs, PLCs, HMIs, and specific software like Siemens Step 7, TIA Portal, and Studio5000. The role also requires designing hardware, supporting build integration, preparing electrical drawings and schematics according to international standards (IEC, UL, NFPA 70E), and creating Bill of Materials (BOM) using E-plan P8 and Electrical AutoCAD. Experience with industrial communication protocols (Ethernet IP/Profinet/Profibus) and GM-specific IT systems (PTPMC, GPMC) is essential for software debugging, interface validation, and troubleshooting. The engineer will act as a controls expert in GM's global equipment design and buyoff process, collaborating with OEMs, integrators, and safety teams for safety buyoffs, risk assessments, and process error-proofing according to GM's health and safety specifications and failsafe design standards. Automation of Fanuc robotics, including programming, validation, safety zones, mastering, and vision applications, is also a key part of the role, along with developing HMI screens for operational sequences, program recovery, and fault management. Domestic travel is required.

Requirements

Bachelor's degree in Electrical Engineering, Mechanical Engineering, or related field of study
Five (5) years of Progressive, post-baccalaureate experience in a related occupation.
Four (4) years of experience with: Siemens Step7 Simatic Manager PLC, SINUMERIK 840D CNC hardware and software PLC and NC programming with safety integrated knowledge, Sinamics VFD and Servo Drives; HMI/SCADA, TIA Portal, WinCC Flex, Starter/Drive ES, CNC Technology, Advanced HMI, toolbox, HMI Pro and Rockwell PLC controllers; RSLogix5000, Design studio, Hardware Design using E-plan, Auto-cad; General Motors Global Common Controls Architecture, Specifications and Standards (GCCS, GCCH) for PLC and G4 Robots, Flexible Assembly Control Systems (FACS) and design, PTPMC, GPMC; Industrial Automation Controls Protocols like Profinet, Profibus, Ethernet and Interfacing with third party specialty devices like Press systems, Nutrunners, Cameras, RFID, laser systems; Process system design development, implementation and testing along with technical problem resolution, root cause analysis and mange key strategic interfaces within vehicle/powertrain automotive system using standard methodologies; Simultaneous engineering activities and equipment reuse, process error proofing including controller safety G risk with cross functional groups; and Supporting Controls run off, approving electrical drawings, and continuously improving quality, cost, system responsiveness and safety.

Responsibilities

Plan, execute, and launch high volume conventional ICE passenger vehicle transmission and Battery Electric Vehicle (BEV) Rechargeable Energy Storage Systems (RESS), fuel cells, and Automated storage retrieval systems (ASRS), Ultium battery cells and components, electrification for GM Global Propulsion Systems (GPS) for U.S., Canada and Mexico Transmission and Electric Drive Unit (DU) plants.
Maintain active engagement and relationship on daily basis with suppliers, integrators of machinery, tooling, hardware and software and GMNA Region (U.S., Canada and Mexico) engineering departments at headquarters and in GM plants for carrying out runoff activities, design reviews, perform functional validations to meet program launch timing.
Incorporate General Motors Flexible Assembly Control Systems (FACS), Global Common Controls Hardware standard (GCCH-1) and Global Common Controls Hardware software (GCCS-1), Fanuc robotics Global 4 standards, Flexible assembly controls systems (FACS) vision and third party controller Interfaces during different phases of program execution.
Engineer, design, evaluate, implement, and optimize current and new automation controls techniques for industrial machining equipment, cutting tools, error proofing systems, and plant floor networks, ancillary equipment (load/unload tooling, washers, special purpose machines), robotics, material handling, parts sorting, conveyors, automated guided vehicles (AGVs), heat treat and, leak test machines, third party manufacturing process equipment, and automation controls technologies including high end 840D Computer Numerically Controlled (CNCs), Programmable Logic Controllers (PLCs), Human Machine Interfaces (HMIs), Siemens Step 7, TIA Portal, Studio5000, Design Studio.
Design hardware and switchgears sizing, support build integration, prepare review electrical drawings and schematics including low voltage switchgears according to International Electrotechnical Commission (IEC) 947 norms and AC/DC power circuits, per Global Machinery industrial Electrical Standard SP-E-60204 and IEC 62061 Safety of Machinery, and electrical UL 508A, NFPA 70E and create Bill of Material (BOM) reports using software tools E-plan P8 and Electrical AutoCAD.
Industrial communication protocols Interface Ethernet IP/Profinet/Profibus networks and GM’s IT Powertrain and Global Production and monitoring controls PTPMC, GPMC, Software Program debug, interface, validation, and controls troubleshooting third party devices such as Press, laser and vision systems, Process data monitoring system, RFID, Printers, 3D barcode scanners etc.
Engage with GM global equipment design and buyoff process as controls expert providing technical directions to execute major program launches, integrate build schema and collaborating with OEM suppliers, integrators and safety expert teams during g-Comply safety buyoff process, g- Risk assessments, simultaneous engineering, process error proofing, checklist and safety controls system validation according to Global Design for Health and Safety Specification (GHS- 1) risk management and process; and Programmable Safety System (PSS) guidelines in accordance with GM’s global Monitored Power Systems (MPS), Safety Controls Systems (SCS) failsafe design standards.
Automate Fanuc robotics to prove automotive applications, load teach part programs, validating robot process paths, Dual Check Safety (DCS) zones, payload, Mastering, and Vision applications 3D IR (infrared) using GM approved Kowa, Matrox and Cognex cameras hardware per GVS requirements, auto backup program methods, develop Human Machine Interface (HMI) screens enabling test sequence of operations, program recovery and faults.