Development & Validation Engineer

General Motors; Warren (MI); On-site; USD 90,000 - 120,000; Full time

Job summary

General Motors in Warren, MI, is seeking a Development & Validation Engineer to lead TRP-related lab testing and DFMEA detection. You will plan, execute, and document tests at cell to pack levels, ensuring alignment with design intent and safety.

This role blends hands-on lab work (about 70%) with strategy and cross-functional coordination with GVE, GPDV, safety, and program teams to drive risk-based priorities and robust test methods.

Qualifications

• Bachelor's degree in Mechanical, Electrical, Chemical Engineering, Materials Science, or related field.
• Minimum 2+ years relevant experience.
• Hands-on lab testing experience with safety emphasis.
• Working knowledge of DFMEA or similar risk-assessment tools.
• Ability to interpret complex test data and communicate conclusions clearly.

Responsibilities

• Plan and execute TRP physical tests in the lab.
• Develop TRP test plans covering cell, module, and pack levels.
• Lead day-to-day testing with hardware readiness and data collection.
• Interpret TRP results with cross-functional teams to define countermeasures.
• Coordinate with safety, design, and systems teams for risk-based prioritization and improvements.
• Document test results with clear reports and summaries.

Skills

DFMEA

Lab testing

Data analysis

Technical writing

Education

Bachelor's degree in Mechanical Engineering

Job description

Job Description

This Development & Validation Engineer is the technical lead for TRP-related physical testing and Design Failure Mode and Effects Analysis (DFMEA) detection within the RESS Development & Validation organization. The role owns planning and execution of TRP lab activities and ensures that results are tightly linked to the DFMEA, enabling risk-based prioritization for propulsion programs. Roughly 70% of the role is hands-on technical execution in the lab and with hardware, and 30% is strategy, leadership, and cross-functional coordination across Global Virtual Engineering (GVE), GPDV, safety, and program teams.

Key Responsibilities

• TRP Physical Test Planning & Execution (Primary - ~70%)
• Develop and maintain detailed TRP test plans and procedures covering cell, module, and pack levels, aligned to program timing and safety requirements.
• Lead day-to-day execution of TRP tests in the lab: hardware readiness, test setup, instrumentation, and on-the-floor issue resolution.
• Ensure test configurations accurately represent design intent, including hardware deviations and associated rationale.
• Drive high-quality data collection, repeatability, and documentation; author clear test reports and technical summaries.
• Partner with safety, design, and systems teams to interpret TRP results, identify failure mechanisms, and define design/test countermeasures.

DFMEA Detection & Risk-Based Prioritization (~20%)

• Act as the TRP physical "detection owner" for relevant DFMEA line items: ensure every significant TRP failure mode has a defined and appropriate physical detection method.
• Use DFMEA scoring (S/O/D and resulting risk rankings) as a prioritization tool -to sort and cluster work-rather than as an "absolute grade" to optimize.
• Regularly review DFMEA rankings with GVE/GPDV partners to decide which TRP tests to run next, which analyses are most valuable, and where method improvements are needed.

Leadership, Collaboration & Ways of Working (~10%)

• Serve as the primary TRP physical voice in the Thermal/TRP workgroup: present status, gaps, and recommendations, and ensure actions are captured and owned.
• Coordinate closely with virtual (GVE) teams to align TRP tests with modeling assumptions, correlations, and capability gaps.
• Contribute to continuous improvement of TRP methods, fixtures, instrumentation, and standard work.

Minimum Qualifications

• Bachelor's degree in Mechanical Engineering, Electrical Engineering, Chemical Engineering, Materials Science, or related field.
• Minimum 2+ years relivant experience
• Demonstrated hands-on experience planning and executing complex lab tests (preferably thermal or abuse testing) with strong attention to safety.
• Working knowledge of DFMEA or similar risk-assessment tools, with experience linking test plans to failure modes.
• Proven ability to interpret complex test data, identify root causes, and communicate technical conclusions clearly in writing and verbally.

Preferred Qualifications

• Experience with TRP, battery safety, or high-energy systems testing (e.g., thermal runaway, abuse, containment, venting).
• Prior ownership of DFMEAs or similar tools for safety-critical systems, including experience with S/O/D scoring and risk-based prioritization.
• Familiarity with GVDP/GPDP and propulsion program execution (scorecards, PRTS, gate deliverables).
• Experience working cross-functionally with GVE, safety, program management, and suppliers.
• Demonstrated capability to influence without authority and drive alignment across multiple stakeholders.

Behavioral Expectations

• Operates with a strong safety and quality mindset in all lab activities.
• Uses data and DFMEA rankings to focus effort on the highest-value work, avoiding "test for test's sake".
• Communicates proactively, escalates risk early, and brings structured options and recommendations.
• Comfortable switching between hands-on lab execution and higher-level risk/strategy discussions with leadership.

Immigration Sponsorship

GM does not provide immigration-related sponsorship for this role. Do not apply for this role if you will need GM immigration sponsorship now or in the future. This includes direct company sponsorship, entry of GM as the immigration employer of record on a government form, and any work authorization requiring a written submission or other immigration support from the company (e.g., H1-B, OPT, STEM OPT, CPT, TN, J-1, etc).

This role is categorized as onsite. This means the selected candidate is expected to report to a specific location on a full-time basis.

The selected candidate will be required to travel About GM

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