Welding & Joining Launch Engineer, Armored Vehicles - GM Defense

General Motors•Warren, MI

1d•Hybrid

About The Position

The Welding & Joining Launch Engineer – Armored Vehicles is responsible for launching and validating welding and joining processes (with emphasis on MIG welding of armored structures) for GM Defense vehicle programs. This role ensures that all weld verification, qualification, and joining processes for armored structures meet GM Defense, customer, and military requirements during prototype, pilot, and production launch phases. Work is performed in a central manufacturing engineering environment, at strategic suppliers, and transitions to the assembly plant / launch site for hands‑on launch support.

Requirements

Bachelor’s degree in Welding, Mechanical, or Manufacturing Engineering, or equivalent years of welding experience in complex metals, armor, etc.
5 or more years of experience in manufacturing/welding engineering, with significant exposure to body or heavy‑structure launch activities.
Good understanding of MIG welding and resistance welding requirements for structural and safety‑critical joints.
Experience with weld verification procedures, weld documentation, and build shop support (e.g., weld maps, torque/weld logs, traceability).
Knowledge of robotic MIG welding systems and resistance welding systems; ability to interface with weld controllers, robots, and data systems during launch.
Body shop or heavy fabrication launch and plant experience, including support of ramp‑up, issue resolution, and process stabilization.
Knowledge of tooling and equipment troubleshooting, particularly fixturing, gun alignment, tip wear, and weld access issues.
Demonstrated knowledge of mechanical and electrical systems used in joining processes (weld controllers, guns, servos, robots, riveters or mechanical fasteners if used).
High level of practical problem solving, using structured methods and data to drive root cause and corrective action.
Strong interpersonal skills, with the ability to work effectively cross‑functionally, cross‑culturally, and with external defense customers/partners.
Strong verbal and written communication skills for technical documentation, launch reports, and training materials.
Ability to create and execute well‑organized validation and launch plans where standardized work is still being refined.
Ability to multitask and manage multiple launch activities in parallel.
Proficiency with standard computer programs (Microsoft Office, Teams, Teamcenter/PLM tools, weld data systems) – intermediate level.
Candidate must be a U.S. Person (U.S. citizen, U.S. permanent resident, asylee or refugee).

Nice To Haves

Knowledge of drawn arc and projection welding, and mechanical joining methods (e.g., flow drill screws, self‑pierce rivets) as applied to armored or mixed‑material structures.
Knowledge of weld data systems and dashboards (e.g., data collection gateways, weld quality monitoring tools) and their use during launch.
Knowledge of GM Welding & Joining Standards and structured launch processes OR similar structured processes in defense/heavy industries.
Experience with defense, armored vehicle, or mission‑critical applications where welding quality and traceability are tightly controlled.
Familiarity with military and customer standards that govern welding, inspection, and acceptance criteria for armored structures.

Responsibilities

Work with Manufacturing Architects, ME, PI, Design, Quality, and Program teams to identify all welding and joining special conditions on armored vehicle programs (critical joints, ballistic zones, fatigue‑critical regions).
Interface with strategic suppliers to verify their welding and joining processes comply with GM Defense standards, customer specifications, and applicable military standards.
Develop and execute the weld verification and qualification strategy for armored structures, including: WPS/PQR development and approval, Weld sample and coupon testing (mechanical and ballistic where applicable), NDE plans (e.g., visual, MT, UT, RT as required by standard or customer).
Develop resource and staffing strategies for welding operations during launch (robotic cells, manual stations, rework capability, inspection resources).
Obtain project approvals and funding using GM/GM Defense systems and processes; maintain alignment with program budgets and milestones.
Define and execute program work testing in GM labs and/or supplier facilities, including weld verification builds, try‑out runs, and process capability checks.
Communicate lessons learned during and on completion of launches and feed them back into GM Defense standards, best practices, and future program planning.
Support the implementation of new welding and joining technologies on armored vehicle programs through engineering, prototype, and launch phases.
Work closely with GM Defense ME and functional areas to define welding and joining system requirements (equipment, fixtures, inspection methods, data systems) for armored vehicle launch.
Assist in the integration, start‑up, and debug of plant floor welding and joining equipment (primarily MIG, plus resistance and mechanical joining where present).
Coordinate business process and re‑engineering projects to streamline welding and joining processes, improve flow, and support ramp‑up to target volumes.
Provide on‑site support during implementation and launch phases at the plant, including parameter verification, troubleshooting, and operator training support.
Report on status of welding and joining systems at operating units, including readiness metrics, open issues, and risk mitigation plans.
Work closely with operating units to improve productivity, cost, quality, and safety for welding operations on armored structures.
Collaborate with other engineers, skilled trades, and managers to accomplish cross‑functional launch projects, provide project cost and timing estimates, and support program timing.
Implement common welding systems, specifications, and standards at launch sites, ensuring consistent application of GM Defense welding requirements.
Read and understand CAD drawings, welding symbols, mechanical layouts, wiring/hosing diagrams, and product designs specific to armored vehicle structures.
Provide technical direction to suppliers and plant teams regarding weld verification steps, acceptance criteria, and rework/repair standards for armor welds.