Manufacturing Process Engineer

GM•Detroit, MI

1d•Onsite

About The Position

The RESS Process Engineer develops, implements, and continuously improves manufacturing processes, equipment, tooling, and standardized work for rechargeable energy storage systems, including battery modules and packs. This role supports advanced propulsion product and process launches from concept and prototype builds through equipment installation, validation, production launch, and steady-state manufacturing. The engineer works closely with Product Engineering, Manufacturing Engineering, Operations, Quality, Maintenance, Controls, suppliers, and Central Manufacturing Engineering to deliver safe, robust, efficient, and capable processes.

Requirements

Bachelor’s degree in Mechanical, Electrical, Manufacturing, Industrial, Chemical, or related Engineering; equivalent relevant experience may be considered.
Experience in manufacturing, process engineering, equipment engineering, battery manufacturing, automotive, or another highly regulated production environment.
Demonstrated ability to analyze complex technical problems and implement practical solutions.
Knowledge of manufacturing processes, design for manufacturability, process capability, and production launch methods.
Knowledge of lean manufacturing, GMS principles, standardized work, PFMEA, Process Control Plans, and error-proofing.
Ability to work effectively with hourly and salaried employees, suppliers, contractors, and cross-functional engineering teams.
Strong written, verbal, organizational, project-management, and presentation skills.
Ability to manage multiple priorities with autonomy, accountability, and sound judgment.
Ability to work safely in a plant environment and comply with applicable high-voltage, chemical, hazardous-material, ergonomic, and environmental requirements.

Nice To Haves

Experience with RESS, lithium-ion battery modules or packs, high-voltage systems, battery testing, leak testing, thermal imaging, or electrical safety.
Experience with automated assembly and test equipment, robotics, PLCs, vision systems, traceability, MES, or data-acquisition systems.
Experience with torque specifications, torque monitoring, dispense systems, and/or welding.
Familiarity with test equipment such as cyclers, hipot systems, leak-test systems, thermal cameras, and/or automated inspection equipment.
Experience using Teamcenter, Delmia, process simulation, plant-floor dashboards, or manufacturing analytics tools.
Experience with root-cause analysis, statistical analysis, capability studies, OEE, and scrap reduction.
Experience leading supplier technical reviews, equipment run-offs, installation, commissioning, and launch activities.
Professional Engineer, Lean, Six Sigma, Red X, or similar certification.

Responsibilities

Develop and optimize RESS assembly, test, inspection, and material-flow processes.
Define process requirements, equipment concepts, tooling needs, layouts, cycle times, and process flow.
Provide technical direction to equipment suppliers, contractors, maintenance, controls, and plant personnel.
Analyze safety, quality, throughput, downtime, scrap, cost, and responsiveness data to identify improvement opportunities.
Troubleshoot equipment and process issues, including test-system failures, leak-test concerns, high-voltage test rejects, thermal-imaging issues, traceability problems, and error-proofing failures.
Develop, review, and maintain PFMEA, Process Control Plans, standardized work, operator instructions, process documentation, and launch deliverables.
Validate process capability and production readiness through trials, run-at-rate activities, audits, and data analysis.
Support product and process changes through the appropriate change-management and production-tryout processes.
Collaborate with Quality and suppliers to investigate defects, establish containment, determine root cause, and implement corrective actions.
Drive lean manufacturing, GMS, 5S, error-proofing, waste elimination, OEE, throughput, and continuous-improvement initiatives.
Use structured problem-solving methods such as Practical Problem Solving, Red X, and Design for Six Sigma as appropriate.
Support maintenance and operations training for equipment troubleshooting, standardized work, and process controls.
Provide daily shop-floor support and participate in production meetings, escalation activities, layered audits, and issue-resolution forums.
Maintain accurate engineering records, lessons learned, equipment documentation, and process changes.
Coordinate multiple projects and communicate status, risks, issues, and countermeasures to leadership and cross-functional stakeholders.