Battery Process Engineer – RESS & Lean

General Motors; Detroit (MI); On-site; USD 90,000 - 150,000; Full time

Job summary

General Motors in Detroit is seeking a Manufacturing Process Engineer to develop and optimize manufacturing processes for RESS battery modules and packs. You will lead cross-functional collaboration with Product Engineering, Manufacturing Engineering, Operations, Quality, and suppliers to deliver safe, robust, and scalable production processes.

The role emphasizes process capability, lean manufacturing, and standardized work, with hands-on shop-floor support and participation in trials, audits,

Qualifications

• Bachelor's degree in a related Engineering field or equivalent experience.
• Experience in manufacturing, process engineering, battery manufacturing, automotive, or another highly regulated production environment.
• Ability to analyze complex technical problems and implement practical solutions.
• Knowledge of lean manufacturing, PFMEA, Process Control Plans, and error-proofing.

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 and high-voltage test rejects.
• 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 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.

Skills

Manufacturing processes

Lean manufacturing

PFMEA

Process control plans

Root cause analysis

Project management

Communication

Education

Bachelor's degree in Engineering

Tools

Teamcenter

Delmia

Process simulation

Manufacturing analytics

Job description

General Motors in Detroit is seeking a Manufacturing Process Engineer to develop and optimize manufacturing processes for RESS battery modules and packs. You will lead cross-functional collaboration with Product Engineering, Manufacturing Engineering, Operations, Quality, and suppliers to deliver safe, robust, and scalable production processes.

The role emphasizes process capability, lean manufacturing, and standardized work, with hands-on shop-floor support and participation in trials, audits,