Casting Process Engineer — Launch & Optimization

generalmotors; Warren (MI); On-site; USD 95,000 - 135,000; Full time

Job summary

General Motors is seeking a Senior Process Engineer – Casting to lead manufacturing process development for new casting programs, equipment, and tooling on the shop floor. You will collaborate with Launch, Quality, Design, Tooling, and suppliers to drive process validation and production launches.

The role requires hands-on experience with foundry processes, LPDC, and relevant simulation tools, plus a BS in engineering or metallurgy.

Qualifications

• 3+ years of professional manufacturing experience.
• Knowledge of foundry processes and applying casting concepts.
• 2+ years in LPDC, precision sand, semi-permanent mold, or similar.
• Familiar with process engineering procedures.
• Basic knowledge of Magma, Flow 3D, and simulation software.
• Basic knowledge of NX or CATIA or similar 3D design software.
• Understanding aluminum chemistry and heat treatment.
• Experience with machine design, tooling, and secondary post processing.
• BS degree in engineering/metallurgy or equivalent.

Responsibilities

• Work with Launch Team, QC, Design, Tooling, and support groups individually and collaboratively.
• Apply foundry concepts in manufacturing environments.
• Support Launch Wall process via Manufacturing Validations, Build Plans, PPAP and related procedures.
• Assist testing and installations of equipment and technologies on and off site.
• Lead analysis of casting defects and provide solutions.
• Assist in process, tooling, and equipment testing and troubleshooting.
• Develop process documentation, process flow diagrams, PCP, PFMEA, TIS, for program launches.
• Analyze first-time quality data and optimize via DOE and related tools.
• Perform NDT and destructive testing procedures for casting investigations.
• Work on site on the shop floor with hands-on equipment.

Skills

Foundry processes

Casting concepts

DOE

PPAP

3D design software

Mechanical concepts

Aluminum chemistry

Education

BS degree in engineering/metallurgy/CS

Tools

Magma

Flow 3D

NX/CATIA

Job description

General Motors is seeking a Senior Process Engineer – Casting to lead manufacturing process development for new casting programs, equipment, and tooling on the shop floor. You will collaborate with Launch, Quality, Design, Tooling, and suppliers to drive process validation and production launches.

The role requires hands-on experience with foundry processes, LPDC, and relevant simulation tools, plus a BS in engineering or metallurgy.