Controls Engineer

Job Description

Insight Global is looking for a Controls Engineer to support advanced automation within a high-volume automotive manufacturing environment. This person will work hands-on with PLCs, HMIs, FANUC robots, vision systems, and other automated equipment while supporting equipment launches, troubleshooting, and continuous improvement.

Responsibilities:

• Develop, modify, and troubleshoot PLC and HMI programs for automated manufacturing equipment.
• Program and support FANUC industrial robots and CRX collaborative robots, ideally CRX30i.
• Integrate and troubleshoot Cognex and/or Keyence vision systems used for inspection, guidance, and part verification.
• Troubleshoot sensors, I/O, safety circuits, interlocks, industrial networks, and other field devices.
• Support equipment installation, startup, debugging, and commissioning on the plant floor.
• Ensure controls systems meet GM GCCS/GCCH standards and customer requirements.
• Troubleshoot PLC, robot, vision, networking, and electrical issues to minimize production downtime.
• Partner with manufacturing, quality, maintenance, and controls teams to resolve equipment issues and improve performance.
• Support FATs, SATs, system testing, and production readiness activities before launch.
• Maintain controls documentation including electrical schematics, I/O lists, safety validation reports, and operating procedures.
• Support continuous improvement efforts around throughput, quality, reliability, and automation performance.

Must Haves:

• 3+ years of Controls Engineering experience in automotive or high-volume manufacturing.
• Experience supporting GM manufacturing facilities or working for an automation/integration company supporting GM.
• GCCS/GSSC certification and experience with GCCH hardware.
• Strong understanding of GM controls standards and assembly-line automation.
• Hands-on PLC programming and troubleshooting experience.
• Experience with Siemens Step 7 and/or Rockwell Allen-Bradley PLCs.
• Experience with FANUC robots, including troubleshooting and recovering robot faults.
• Experience with Cognex and/or Keyence vision systems.
• Familiarity with FACS, EtherNet/IP, industrial networks, HMIs, and controls architecture.
• Experience with equipment commissioning, debugging, and production support.
• Familiarity with CITI Logic, G-Comply, and TIS/SCS electrical tasks.