Senior Process Engineer - Casting

General Motors; Lansing (MI); On-site; USD 110,000 - 150,000; Full time

Job summary

General Motors in the United States is seeking a Senior Process Engineer - Casting to lead manufacturing processes, equipment and tooling for castings, partnering across GM teams, vendors and suppliers to transfer technology from development to production.

This onsite role requires 3+ years in manufacturing, experience in low pressure die casting or sand casting, and familiarity with DOE, PPAP and quality systems. Expect about 50% travel and hands-on shop-floor work on casting projects.

Qualifications

• 3+ years of professional experience in a manufacturing environment.
• Demonstrated knowledge of foundry processes and casting concepts.
• 2+ years in Low Pressure Die Casting, Precision Sand, Semi Permanent Mold or similar.
• Knowledge of process engineering procedures and disciplines.
• Basic knowledge of Magma, Flow 3D, simulation software.
• Basic knowledge of NX or Catia or any 3D design software.
• Knowledge of aluminum chemistry, heat treat, metallurgical processes.
• Understanding of machine design, process equipment and tooling.
• BS degree (engineering, metallurgical or related) or equivalent experience.

Responsibilities

• Work individually on programs yet collaborate with Launch Team, QC, Design and Tooling.
• Demonstrate technical knowledge of foundry processes in a manufacturing environment.
• Support Launch Wall process via Manufacturing Validations and PPAP.
• Assist testing and installations of equipment and tooling on and off site.
• Lead, support and present analysis of casting defects.
• Assist in process, tooling and equipment testing and troubleshooting.
• Develop process documentation, PCP, PFMEA, TIS for launches.
• Analyze first time quality data and optimize via DOE, Red X and stats.
• Perform non and destructive testing procedures for casting investigations.
• On-site work on shop floor with hands-on equipment.

Skills

Foundry processes

DOE

PPAP

Manufacturing validations

Equipment testing

Education

BS degree in engineering or metallurgy

Tools

Magma

Flow 3D

NX

Catia

Job description

Job DescriptionAt General Motors, our product teams are redefining mobility. Through a human-centered design process, we create vehicles and experiences that are designed not just to be seen, but to be felt. We’re turning today’s impossible into tomorrow’s standard -from breakthrough hardware and battery systems to intuitive design, intelligent software, and next-generation safety and entertainment features. Every day, our products move millions of people as we aim to make driving safer, smarter, and more connected, shaping the future of transportation on a global scale.

SENIOR PROCESS ENGINEER - CASTING

The Role

The Launch Process Engineering Team excels in the development, testing, implementation and execution of new casting programs, platforms and technology. This group is unique in that by working with and across multiple levels of the GM technical groups, vendors and suppliers, the complex problems of casting projects are developed into controlled manufacturing processes. The Specific Purpose of this position is to perform casting manufacturing projects by following a systematic engineering process of evaluation, development, validations, technology transfer leading into and supporting the production launch and processing. Specifically responsible and directly involved in the development of manufacturing processes, equipment, tooling and alternatives, sequences, operations, utilizations for the production of castings.

What You'll Do

• Ability to work individually on specific programs yet collaboratively with Launch Team, QC, Design, Tooling, and other support groups
• Demonstrate technical knowledge of foundry processes and ability to apply concepts in a manufacturing environment
• Support Launch Wall process via Manufacturing Validations, Build Plans, PPAP and related engineering procedures
• Support testing and installations of equipment, tooling and technologies both on and off site
• Lead, support and present the analysis of casting defects
• Assist in process, tooling and equipment testing, troubleshooting and implementations
• Develop process documentation, Process flow diagrams, PCP, PFMEA, TIS, and related technical documents as necessary for a program launch
• Analyze first time quality data and optimize processes using DOE, Red X, and related statistical tools
• Perform both Non and destructive testing procedures for casting investigation and analysis (leak testing, x ray, CT, thermal, lab specimen prep, chemistry, density, mechanical, etc)
• On site work, working on shop floor, hands on equipment, understanding of casting shop activity.

Your Skills And Abilities (required Qualifications)

• 3+ years of professional experience in a manufacturing environment
• Demonstrated knowledge of foundry processes and ability to apply casting concepts in a manufacturing environment
• 2+ years of professional experience in Low Pressure Die Casting, Precision Sand, Semi Permanent Mold or similar, tooling, process, quality, or project management experience.
• Knowledge of process engineering procedures and disciplines
• Basic knowledge of Magma, Flow 3D, simulation software
• Basic knowledge of NX or Catia or any 3D design software
• Effective and functional knowledge of aluminum chemistry, heat treat, metallurgical processes
• Demonstrated understanding of mechanical concepts involving machine design, process equipment, tooling, and secondary post processing
• BS degree (engineering, metallurgical, computer science) or equivalent experience is required

What Will Give You a Competitive Advantage (preferred Qualifications)

• Training in aluminum metallurgy
• Prior experience in Low Pressure Die Casting, Precision Sand or Semi Permanent Mold
• Prior experience in injection molds
• Prior experience in castings or Giga/Structural castings
• Training in flow simulations ( Magma, Flow 3d)
• Training in 3D design software
• Mechanical properties testing and procedures
• Background in Aluminum chemistry is encouraged
• Training in Problem solving

GM does not provide immigration-related sponsorship for this role.

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 at least 50% or more on a frequent basis. This job is not eligible for relocation benefits. Any relocation costs would be the responsibility of the selected candidate.

About GM

Our vision is a world with Zero Crashes, Zero Emissions and Zero Congestion and we embrace the responsibility to lead the change that will make our world better, safer and more equitable for all.

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