Job Description
The Controls Engineer – Bedford GPS is responsible for the design, implementation, troubleshooting, and continuous improvement of electrical control and automation systems that support aluminum casting and machining operations at the Bedford plant. The role applies GM common controls standards to ensure safe, reliable, and efficient operation of equipment across CSS, DCN, HIDC, and related areas, while providing technical support to manufacturing, maintenance, and engineering teams.
Controls & Automation Engineering
Design, program, and troubleshoot PLC- and HMI‑based control systems for casting, machining, material handling, and auxiliary equipment.
Configure and support industrial networks, including communication with robots, drives, safety devices, and plant floor systems.
Implement and maintain servo, motion control, and drive systems to meet safety, quality, throughput, and uptime targets.
Support Fanuc robot programming and troubleshooting where applicable (material handling, deburr, vision‑guided applications, etc.).
Equipment Launch, Changes, and Continuous Improvement
Support new equipment and major modification projects from requirements and SOR development through design review, FAT/SAT, installation, run‑off, and production release.
Analyze product, process, and technology to define best manufacturing methods and protect the manufacturing process (safety, quality, throughput, cost).
Lead or support controls‑driven CI projects (cycle time reduction, fault elimination, error‑proofing, OEE improvement), using downtime data and plant floor analytics to identify opportunities.
Ensure documentation and system management for all assigned areas, including current PLC programs, HMI applications, network drawings, electrical prints, and UD&C backups per GM standards.
Plant Support & Troubleshooting
Provide advanced controls troubleshooting support when maintenance cannot resolve equipment issues, including online debugging, data collection, and root‑cause analysis.
Partner with operations, maintenance, and quality to restore production, support repair processes, and ensure equipment is capable of producing parts that meet specification.
Support and maintain plant floor systems interfaces (e.g., error proofing, Andon, production monitoring, PT PM&C, upload/download & compare) in collaboration with PFS and IT teams.
Safety, Compliance & Standards
Apply and uphold GM common controls standards, machine safety standards, lockout/tagout, and MPS validation requirements in all designs and changes.
Support corporate and plant safety programs, including risk assessments, safety validation, and resolution of controls‑related safety issues.
Support manufacturing cybersecurity and network best practices in cooperation with Manufacturing Cybersecurity and plant IT teams.
Training, Collaboration & Communication
Provide on‑the‑job training and technical guidance to electricians, technicians, and other engineers on controls systems, diagnostics, and standards.
Collaborate closely with Process, Mechanical, Reliability, Quality, and Production teams to ensure controls solutions are robust, maintainable, and aligned with plant strategies.
Maintain clear, concise technical documentation and communication, including change logs, TIS/STS updates, project status, and lessons learned.
Bachelor’s degree in Engineering (Electrical, Controls, Mechanical, Computer, or related discipline) or equivalent experience.
2+ years of experience as an Engineer in an industrial/manufacturing environment (co‑op/internship plus post‑graduate experience considered in aggregate).
Demonstrated ability to diagnose and resolve complex controls and automation issues in a high‑volume manufacturing environment.
Strong analytical, problem‑solving, and organizational skills, with the ability to manage multiple projects and priorities simultaneously.
Effective communication and interpersonal skills to work across operations, maintenance, engineering, and suppliers.
Experience in automotive or industrial manufacturing, ideally in casting, machining, or similar process equipment.
Experience with Fanuc robots (setup, path programming, recovery, and error‑proofing), including integration with PLCs.
Experience supporting or implementing error‑proofing, Andon, and production monitoring systems in a unionized manufacturing environment.
Demonstrated use of data‑driven problem solving to reduce downtime and improve quality.
Onsite at Bedford GPS with frequent interaction on the plant floor (casting, machining, and support areas).
Support for multi‑shift operations, including occasional off‑shift, weekend, and holiday work during launches, major shutdowns, or critical downtime events.
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