Senior Controls Engineer- Body Shop

Description
This is a 2nd shift opportunity
This job may be eligible for relocation benefits
GM DOES NOT PROVIDE IMMIGRATION-RELATED SPONSORSHIP FOR THIS ROLE. DO NOT APPLY FOR THIS ROLE IF YOU WILL NEED GM IMMIGRATION SPONSORSHIP (e.g., H-1B, TN, STEM OPT, etc.) NOW OR IN THE FUTURE.
Onsite: This role is categorized as onsite. This means the successful candidate is expected to report to Orion, MI on a full-time basis.
The Role
The Senior Controls Engineer- Body Shop is responsible for providing advanced controls engineering leadership and technical oversight within a highly automated automotive body shop environment. This role serves as a key technical expert supporting robotic welding, material handling, joining technologies, and automated production systems. The position requires a high degree of independent judgment and technical authority to achieve safety, quality, cost, throughput, and launch objectives while ensuring the long-term reliability and maintainability of body shop equipment and controls systems.
What You'll Do

• Lead controls engineering strategy and execution for body shop manufacturing systems
• Serve as the technical authority for PLC, robotics, and network architecture standards.
• Manage and execute complex electrical and controls projects including new installations, major upgrades, model change activities, throughput improvements, and lifecycle replacements.
• Develop and approve cost estimates, investment forecasts, business cases, and appropriation requests for capital projects.
• Provide technical mentorship to Controls Engineers, Automation Engineers, and Skilled Trades across multiple shifts.
• Lead root cause analysis and resolution of complex equipment and system failures.
• Drive continuous improvement initiatives utilizing statistical methods and data-driven decision making.
• Coordinate with Manufacturing Engineering, corporate engineering organizations, and suppliers on new model planning, CQPI, sourcing, and equipment validation.
• Establish and manage project support plans between plant operations, corporate engineering, and contractor resources.
• Represent Engineering in plant leadership meetings and cross-functional business planning activities.
• Influence plant-wide goals through Business Plan Deployment and cross-functional alignment.
• Support implementation of Global Manufacturing Systems and Quality Network initiatives to improve operational excellence.
• Oversee development and adherence to engineering standards, documentation, and best practices.
• Develop and monitor project schedules, risk mitigation plans, and execution timelines.
• Provide input into plant capital planning and Central Manufacturing Engineering budgets.
• Ensure long-term reliability, maintainability, and cost efficiency of manufacturing equipment and infrastructure.
• Drive energy efficiency, operational cost reduction, and maximum throughput strategies.
• Partner with Plant Training teams to develop and deploy training for new technologies introduced to the facility.
• Champion safety as the highest priority, enforcing safe work practices and driving improvements in ergonomics, health, safety, and housekeeping.
• Maintain strong working relationships with hourly employees, union leadership, plant management, suppliers, and external support organizations.

Your Skills and Abilities (Required Qualifications)

• Advanced ability to program, troubleshoot, and optimize Rockwell/Allen-Bradley ControlLogix PLC systems in high-volume automotive manufacturing environments.
• Advanced troubleshooting and programming experience with FANUC robotic systems, including robot path recovery, fault diagnostics, and production optimization.
• Strong understanding of welding systems, weld controllers, weld schedules, and robotic welding applications?
• Expert ability to read, interpret, and modify electrical schematic and controls documentation.
• Advanced troubleshooting experience with automated body shop manufacturing systems, material handling equipment, and conveyor controls.
• Strong knowledge of industrial communication networks including Ethernet/IP, DeviceNet, ControlNet, and integrated robot-to-PLC communication.
• Experience supporting safety-rated control systems, robot safety zones, interlocks, and machine safeguarding requirements.
• Strong analytical and structured problem-solving capabilities utilizing root cause analysis and data-driven methodologies.
• Effective leadership, communication, and interpersonal skills with the ability to influence cross-functional teams.
• Willingness to work 2nd shift
• Willingness to support weekend or extended hours during critical production and project phases.

Preferred Qualifications

• Five or more years of experience in automotive body shop, welding, or assembly manufacturing operations.
• Experience supporting robotic welding cells, framing systems, underbody/body-side lines, or final body assembly processes.
• Experience leading automation strategies, major equipment installations, or large capital projects in a body shop environment.
• Bachelor's degree in Electrical Engineering, Mechatronics Engineering, or equivalent technical experience.
• Experience with manufacturing systems integration including (MES, SCADA, data acquisition)
• Knowledge of dimensional quality systems, automated measurement technologies, and body build quality requirements.
• Demonstrated experience leading, mentoring, or supervising engineering and technical teams.
• Experience supporting new vehicle launches, tooling integration, and production ramp-up activities

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