General MotorsCase study · Project Delivery
Automation Validation & Equipment Buyoff
Holding new automation to its throughput and production requirements, and taking it through buyoff with suppliers.
- My role
- Controls Engineer
- Timeframe
- General Motors · Oct 2023 – Present
- Team / context
- General Motors, Warren, MI
- Tech stack
- Automation validation · Buyoff checklists · Supplier management · PLC · Open issues tracking · Safety
01
Overview
New automation isn't accepted on a supplier's word. At General Motors I test, validate, and audit automation systems to make sure they meet the throughput and production requirements they were bought for.
I make sure suppliers meet their project deliverables through each project phase, complete the engineering execution checklists that the equipment buyoff process requires, and modify controls logic when process changes are approved. Persistent issues are escalated to senior leadership and tracked on the open issues list until they're closed.
02
The problem & objective
Automation is delivered by suppliers across several project phases. Without a disciplined acceptance process, equipment could be accepted before it meets its throughput and production requirements.
The objective is to prove every system against its requirements, confirm every supplier deliverable, and keep every open issue owned until it's resolved.
03
My role & responsibilities
Controls Engineer. Delivered as part of my role as Controls Engineer at General Motors.
- Test, validate, and audit automation systems against throughput and production requirements
- Make sure suppliers meet project deliverables in each project phase
- Complete the engineering execution checklists required for equipment buyoff
- Modify controls logic as needed to implement approved process changes
- Escalate persistent issues to senior leadership and track them on the open issues list
- Take part in safety talks and team meetings to build safety awareness
04
Approach & process
Test against requirements
Run and audit each system against its throughput and production requirements.
Hold suppliers to deliverables
Check supplier deliverables at each project phase, not just at the end.
Document the buyoff
Complete the engineering execution checklists that the buyoff process requires, so acceptance rests on evidence.
Control changes
Modify controls logic only to implement approved process changes.
Escalate and track
Raise persistent issues with senior leadership and track them on the open issues list until they're closed.
05
Key features & deliverables
Validated automation
Systems tested and audited against throughput and production requirements.
Completed buyoff checklists
Engineering execution checklists completed for equipment buyoff.
Open issues list
Persistent issues escalated and tracked with senior leadership.
06
Challenges & how I solved them
| Challenge | How I solved it |
|---|---|
| Many suppliers, many project phases | Checking deliverables phase by phase, and recording them in buyoff checklists, keeps each supplier accountable. |
| Some issues don't go away on their own | Persistent issues are escalated to senior leadership and tracked on the open issues list until they're resolved. |
07
Results & impact
- Automation held to throughput and production requirements before acceptance
- Equipment buyoff backed by completed engineering execution checklists
- Persistent issues escalated and tracked to closure with leadership
08
Skills demonstrated & lessons learned
Skills demonstrated: Automation validation · Equipment buyoff · Supplier management · PLC programming · Issue escalation · Safety awareness
Acceptance is an engineering task. A completed checklist is better evidence than a demo that went well.
Get in touch
Let's work together
I'm open to Controls Engineer, Automation Engineer, Software Engineer, and Full-Stack Developer roles, remote or on-site. If you're building something where automation and software meet, I'd like to hear about it.
elshark.atef@gmail.com