Senior Manufacturing Engineer-Manufacturing Process Analysis

General Motors • Warren, MI

2d • Hybrid

About The Position

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. The Senior Manufacturing Engineer serves as a simulation and analysis resource for manufacturing engineering organizations, applying advanced modeling to manufacturing process development, troubleshooting, product validation, and future technology initiatives. The role suits a technically strong, research-oriented engineer who can work through complex, open-ended problems, ambiguity, and evolving requirements while developing innovative solutions.

The engineer partners with manufacturing, plant, product design, materials, and process engineering teams to define problems and analysis objectives. They conduct and develop engineering analyses, research appropriate methods, correlate simulation results with real-world data, and communicate recommendations to internal customers and leadership. The role may also include providing technical guidance, training, mentoring, or coordinating a small group of engineers. This position is categorized as hybrid, with the selected candidate expected to report to a specific location at least three times per week or as directed by their manager. Travel is less than 25%. Relocation benefits are available to candidates who qualify under company policy. GM does not provide immigration-related sponsorship for this role.

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.
• 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 in Mechanical Engineering, Materials Engineering, Manufacturing Engineering, or a related discipline.
• 5+ years of professional experience applying engineering simulation methods.
• 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, selecting 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.

Benefits

• Relocation benefits are available for candidates who qualify under company policy.
• GM describes benefits and well-being resources as available from day one; further details are provided through its Total Rewards resources.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior