Senior Process Controls Engineer

GM • Warren, MI

20h • Onsite

About The Position

The Role As a Senior Process Controls Engineer, you will lead the development, execution, and continuous improvement of manufacturing controls across new and existing programs. This role supports both centralized manufacturing engineering and plant operations, requiring a high degree of technical expertise, creative problem‑solving, and independent judgment. You will serve as a subject‑matter expert in controls and automation technologies while mentoring junior engineers and driving successful program launches. What You’ll Do Lead new program execution, including SOR preparation, forecasting, controls and robotics design, equipment build/run‑off, and buyoff. Oversee the design, construction, integration, and plant installation of controls systems to support successful launches and long‑term performance. Stay current with emerging technologies in PLCs, HMIs, industrial networks, robotics, and vision systems to drive innovation and plant readiness. Manage program deliverables to meet timing milestones and provide clear project report‑outs to senior leadership. Provide technical support for existing programs, including troubleshooting, root‑cause analysis, and optimization of controls systems. Offer technical direction and mentorship to less‑experienced controls engineers to upskill the team and support project execution. Design, review, and troubleshoot electrical control systems for manufacturing equipment. Contribute to the development and testing of advanced process technologies that improve efficiency, quality, and safety. Lead project management activities for controls deliverables, ensuring alignment across engineering, operations, and cross‑functional partners.

Requirements

• Experience across multiple Manufacturing Engineering (ME) and plant assignments (4+ years), with a track record of successful individual and team-based achievements.
• Strong engineering, critical thinking, and analytical skills to solve unusual and difficult problems.
• Effective communication and interpersonal skills with the ability to influence and align cross-functional partners.
• Working knowledge of plant floor systems, including Production Monitoring and Control, Andon Systems, Upload/Download and Compare, Throughput and Material Call.
• Prior work experience in tooling systems with knowledge of Common Controls Hardware and Common Controls Software Standards.
• Understanding of manufacturing processes and parts design interface for applications, including Rockwell PLCs, Fanuc robot programming, and CNC experience (Siemens Sinumerik).
• Bachelor’s degree or equivalent relevant experience.
• Experience with Manufacturing Engineering plant floor controls systems, including hands-on automation controls design and project execution from concept through implementation.
• Self-motivated, able to multitask, and provide clear technical direction to others, both face-to-face and remotely.
• Proven project management skills, including planning, execution, and risk/issue management.

Nice To Haves

• Strong knowledge of GM systems and Platform with respect to GM Controls architecture.
• Deep understanding of GM manufacturing processes in shops and related quality systems.
• Strong working knowledge of manufacturing-related IT systems such as GSIP, GEPICS, GPM&C, PTPM&C, PAS, FACS, QDAS/GDIS, and MASS.
• Working knowledge of GMIT Launch Processes and how they interface with controls and plant floor systems.
• Experience with GM Global Common Controls Architecture, Cognex and Matrox vision system programming, and engine manufacturing processes (cranks, heads, blocks, engine assembly).

Responsibilities

• Lead new program execution, including SOR preparation, forecasting, controls and robotics design, equipment build/run‑off, and buyoff.
• Oversee the design, construction, integration, and plant installation of controls systems to support successful launches and long‑term performance.
• Stay current with emerging technologies in PLCs, HMIs, industrial networks, robotics, and vision systems to drive innovation and plant readiness.
• Manage program deliverables to meet timing milestones and provide clear project report‑outs to senior leadership.
• Provide technical support for existing programs, including troubleshooting, root‑cause analysis, and optimization of controls systems.
• Offer technical direction and mentorship to less‑experienced controls engineers to upskill the team and support project execution.
• Design, review, and troubleshoot electrical control systems for manufacturing equipment.
• Contribute to the development and testing of advanced process technologies that improve efficiency, quality, and safety.
• Lead project management activities for controls deliverables, ensuring alignment across engineering, operations, and cross‑functional partners.

Benefits

• From day one, we're looking out for your well-being–at work and at home–so you can focus on realizing your ambitions.
• Learn how GM supports a rewarding career that rewards you personally by visiting Total Rewards resources .

What This Job Offers

• Job Type: Full-time
• Career Level: Senior
• Number of Employees: 5,001-10,000 employees