Senior Manufacturing Engineer-Manufacturing Process Analysis

General Motors•Warren, MI

1d•Hybrid

About The Position

At General Motors, our product teams are redefining mobility. Through a human-centered design process, we create vehicles and experiences that are designed not just to be seen, but to be felt. We’re turning today’s impossible into tomorrow’s standard —from breakthrough hardware and battery systems to intuitive design, intelligent software, and next-generation safety and entertainment features. Every day, our products move millions of people as we aim to make driving safer, smarter, and more connected, shaping the future of transportation on a global scale. The Manufacturing Process Analysis team develops physics-based analysis methods to understand, predict, and improve critical manufacturing processes for automotive propulsion systems, including internal combustion engines, electric motors, and batteries. This role is ideal for a highly technical, research-oriented engineer who enjoys solving complex, open-ended problems. The team serves as a simulation and analysis resource for manufacturing engineering organizations, applying advanced modeling techniques to support manufacturing process development, troubleshooting, product validation, and future technology initiatives. The successful candidate will combine strong engineering fundamentals, simulation expertise, intellectual curiosity, and a passion for solving challenging technical problems. This role is well-suited for engineers who thrive in environments with ambiguity, enjoy continuous learning, and are motivated by developing innovative solutions where established methods may not yet exist.

Requirements

Bachelor's degree in Mechanical Engineering, Materials Engineering, Manufacturing Engineering, or a related engineering discipline.
3+ years of professional experience applying engineering simulation methods, including FEA, CFD, or related modeling tools, with 5+ years preferred.
Experience developing, interpreting, validating, or applying engineering models to solve technical problems.
Strong analytical and problem-solving skills.
Ability to work independently in environments with incomplete information and evolving requirements.
Strong technical communication and collaboration skills.

Nice To Haves

Master's degree or PhD preferred.
Master's degree or PhD in Mechanical Engineering, Materials Engineering, Manufacturing Engineering, or related discipline.
Experience with heat treatment simulation, metallurgy, phase transformation, distortion prediction, or material behavior analysis.
Experience with computational fluid dynamics (CFD), heat transfer, or thermal analysis.
Experience supporting manufacturing processes such as casting, machining, welding, assembly, electric motor production, battery manufacturing, or propulsion systems manufacturing.
Experience validating simulations against experimental, inspection, plant, or production data.
Familiarity with tools such as Abaqus, Altair HyperWorks, STAR-CCM+, Dante, NX, CAD software, Teamcenter, or similar platforms.
Experience developing automation tools or analysis workflows using Python or other programming languages.
Experience mentoring engineers or leading technical projects.

Responsibilities

Partner with manufacturing, plant, product design, materials, and process engineering teams to define complex technical problems and analysis objectives.
Conduct FEA, CFD, thermal, structural, and multiphysics analyses to identify root causes and develop practical solutions.
Investigate heat treatment, material phase transformation, thermal gradients, residual stress, distortion, ductility, and other material and process behaviors.
Apply simulation to manufacturing processes such as casting, machining, assembly, welding, and fluid flow.
Develop analysis approaches independently, including selection of appropriate physics, assumptions, boundary conditions, material models, and solution methods.
Perform research and literature reviews to support model development and technical recommendations.
Create and improve analysis methods and workflows using tools such as Abaqus, Altair HyperWorks, STAR-CCM+, Dante, NX CAD, and Python.
Automate preprocessing, solver execution, post-processing, and reporting where appropriate.
Correlate simulation results with test, inspection, plant, experimental, or production data.
Post-process and interpret results, prepare technical presentations, and communicate conclusions to internal customers and leadership.
Provide technical guidance, train others, and mentor or coordinate the work of a small group of engineers as needed.