Senior Controls Engineer

Senior Controls Engineer

Livermore, CA

GILLIG buses play a critical role in the environmental and social initiatives in communities across the nation. GILLIG is on the forefront in the transition to zero-emission vehicles and has an unmatched reputation in the industry for quality, reliability, durability, service, and support. From initial design through final assembly, each GILLIG bus is designed and built in Livermore, CA.

Why Gillig

• Leader in environmentally friendly mobility solutions including battery electric, hybrid electric, near-zero CNG and clean diesel transit buses
• Renowned for its inclusive team/family-oriented culture
• Stable, successful, and growing organization – a Bay Area business for over 132 years!
• Flexible schedules (*depending on project needs)
• Excellent compensation including company paid medical premiums, generous retirement plan and other comprehensive benefits

Department Overview

GILLIG Engineering is responsible for the development, customization, and configuration of GILLIG's clean technology heavy-duty transit buses. We are committed to developing the most reliable vehicles that connect communities, eliminate congestion, and contribute to a greener environment. Our engineers are engaged in designing, analyzing, testing, launching, and problem solving across a wide range of technical areas.

The Controls Team is responsible for the development and integration of advanced control algorithms for critical body functions across all vehicle platforms. Working closely with cross-functional teams, they conduct rigorous testing and validation to ensure these algorithms meet functional requirements, comply with regulatory standards, and contribute to delivering high-quality, reliable transit buses to the market.

About The Role

We are looking for a Senior Controls Engineer who will lead the development of control algorithms for critical body functions across all vehicle platforms. You will be directly involved in developing, testing, and releasing algorithms for various systems, subsystems, and components – including the HMI driver display, passenger doors, ramp, interior lighting, HVAC, vehicle safety systems, LV power distribution, etc. – ensuring that all algorithms meet safety, regulatory, reliability, and performance requirements. You will also lead the creation of advanced vehicle diagnostics and detailed troubleshooting guides to support technicians in resolving bus issues effectively.

This is a hands-on, on-site role at our Livermore, CA plant and reports to the Controls Engineering Manager but may also receive directions and guidance from other senior and/or staff engineers.

Technical Focus

Body Controls

Develop and implement control algorithms for vehicle body systems, ensuring seamless integration of electrical, thermal, and mechanical subsystems and components, including HVAC, lighting, doors, and safety systems.

In This Role You Will

• Create functional requirements for vehicle behavior to ensure compliance with program requirements and standards. Define communication interfaces and protocols for all vehicle systems, while ensuring communication network loads and traffic remain within design limits
• Develop, test, and validate control algorithms to improve both existing and future vehicle capabilities
• Participate in DFMEA, FMEA-MSR, hazard, and risk assessments to enhance fault detection and minimize potential failures
• Create environments to design, test, and refine electronic control systems prior to their integration on a vehicle
• Actively contribute to software-specific design test plans. Perform hands-on troubleshooting, testing, and validation activities both onsite and in the field. Collaborate with engineers to bring up prototype vehicles and address issues effectively
• Lead the development of advanced vehicle diagnostics and create detailed troubleshooting guides to support efficient issue identification and resolution. Provide technical input to generate vehicle manuals, ensuring accuracy and completeness
• Architect and maintain control development processes, including version control, automated code review, and regression testing
• Release software through the Product Lifecycle Management (PLM) system while maintaining traceability throughout the entire bus lifecycle
• Lead continuous improvement efforts for control systems to enhance vehicle reliability, performance, and customer satisfaction. Analyze field data and feedback to identify areas for improvement

Scope Of The Role

• Autonomy: Ability to work independently with review at critical points.
• Technically Minded: Apply industry practices and standards (NFPA, NEC, APTA, etc.) and provide input and advice to other staff members on industry practices and standards. Exhibit advanced wide-ranging experience, using in-depth professional knowledge, acumen, concepts and company objectives to develop, resolve complex models and procedures.
• Time Management: Work productively to deliver projects on schedule and on budget.
• Communication: Collaborate and teach up, down and across the organization to help raise the skills and knowledge of the GILLIG team. Adapt style to differing audiences and adept at persuasion on complex subjects.
• Complexity: Responsible for a certain set of commodities or design elements within the team. Work on problems of diverse scopes where analysis of information requires evaluation of multiple factors. Devise solutions based on limited information and precedents and adapt existing approaches to resolve issues. Use engineering principles, judgment, and interpretation to select the right course of action.
• Quality & Standards: Technical documentation and deliverables are accurate and complete. Released designs are cost effective, manufacturable, serviceable, meet all performance objectives, & meet customer requirements.

Basic Qualifications

• Bachelor's or advanced degree in Engineering
• Minimum 5 years of experience in the engineering industry, preferably in automotive, commercial, or heavy-duty vehicle design
• Fluent with BOM, documentation control, and revision/version management. Experience with configure-to-order products and modular BOM management is a plus
• Experience working with major component suppliers, engineering service suppliers, testing suppliers, and product validation engineers
• Strong, hands-on experience in troubleshooting, product assembly, prototyping, testing, and validation, both onsite and at remote locations
• Expertise with open and closed loop control systems for sensors, actuators, body controllers, and ECUs, including proficiency in CAN-Bus, LIN, and Ethernet communication protocols
• Prior development work with ladder logic controls (e.g., Allen-Bradley, Siemens PLC), software development using C/C++, or model-based development (e.g., MATLAB Simulink)
• Prior experience with integrating controls systems with low and high voltage automotive hardware, such as DCDC converters, motors, inverters, Li-ion batteries, and high-power chargers
• High operating knowledge of industry standards such as FMVSS, NHTSA, DOT, NFPA, SAE, and NEC
• Heavy-duty, transit and/or commercial vehicle experience is a plus

Work Environment:

• Ability to lift 25 lbs.
• Prolonged periods of sitting/standing at a desk and working on a computer
• Regularly required to sit, stand, and walk and occasionally kneel or squat
• The ideal candidate must be able to complete all physical requirements of the job with or without reasonable accommodation.
• Limited travel may be required
• Must be able to navigate manufacturing environment, comfortable around heavy machinery, tools, etc.
• Must be able to wear Personal Protective Equipment, (i.e. safety glasses, bump caps, hearing protection, etc.)
• Standard start time between 6:00 (negotiable)

Expected Compensation

$128,000 - $165,000/annual salary + premium benefits

Pay offered may vary depending on multiple individualized factors, including market location, job classification, job-related knowledge, skills, and experience. The total compensation package for this position may also include other elements dependent on the position offered. Details of participation in these benefit plans will be provided if a candidate receives an offer of employment.