Casting Process Engineer – Development Program

GM•Saginaw, MI

7h•Onsite

About The Position

The Casting/Manufacturing Engineering team’s Casting Process Engineer role is a two-year casting development program. The Process Engineer position is a direct-hire role aligned to a designated home location within our casting manufacturing organization. As part of the onboarding and development strategy for this role, the successful candidate will participate in a structured two-year rotational experience consisting of four assignments across three manufacturing sites. The rotational assignments are intended to accelerate technical development, expand enterprise casting knowledge, and deepen understanding of GM manufacturing systems and operations. Following completion of the rotational experience, the employee will be placed in a full-time assignment at their original home location. Potential assignments may include: Quality Engineering, Project Launch Execution Support, Production Process Engineering Support – Casting processes, Production Process Engineering Support – Machining Processes, Tooling Design, Melting/Metallurgy lab. The Process Engineering Team excels in the development, testing, implementation and execution of new casting programs, platforms, and technology. This group is unique in that by working with and across multiple levels of the GM technical groups, vendors and suppliers, the complex problems of casting projects are developed into controlled manufacturing processes. The specific purpose of this position is to perform casting manufacturing projects by following a systematic engineering process of evaluation, development, validations, technology transfer leading into and supporting the production launch and processing. Specifically, the individual would be responsible and directly involved in the development of manufacturing processes, equipment, tooling and alternatives, sequences, operations, utilizations to produce castings.

Requirements

Pursuit of a Bachelor’s or Master's degree in Manufacturing Engineering, Mechanical Engineering, Material Science, Industrial Engineering, Engineering Technology, or Metallurgy
Must be graduating between May 2025 and December 2026
Able to work full-time, 40 hours per week and overtime when required
Must be willing to work in a plant environment

Nice To Haves

Experience in a plant environment or similar
Training in foundry processes
Training in process engineering procedures and disciplines
Basic knowledge of Magma, Flow 3D, simulation software
Basic knowledge of NX, Catia or any 3D design software
Degree courses with a metal casting focus

Responsibilities

Ability to work individually on specific programs yet collaboratively with the Process Engineering Team, Launch Team, Quality, Design, Tooling, Melting and Metallurgy, Product Engineering, and other support groups
Support Launch Wall process via Manufacturing Validations, Build Plans, PPAP and related engineering procedures
Support testing and installations of equipment, tooling and technologies both on and off site
Lead, support and present the analysis of casting defects
Assist in process, tooling and equipment testing, troubleshooting and implementations
Develop process documentation, Process flow diagrams, Control plans, PFMEA, standard work documents, and related technical documents as necessary for a program launch
Analyze first-time quality data and optimize processes using DOE, DFSS green belt, and related statistical tools
Manage Process Controls plans, QS-Stat and Flexnet software, and quality systems
Perform both non-destructive and destructive testing procedures for casting investigation and analysis (CMM, leak testing, x ray, CT, thermal, lab specimen prep, chemistry, density, mechanical, etc.)
On site work, working on shop floor, hands on equipment, understanding of casting shop activity.