Senior Manufacturing Engineer-Manufacturing Process Analysis

Description
At 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.
The Role
The Manufacturing Process Analysis team develops physics-based analysis methods to understand, predict, and improve critical manufacturing processes for automotive propulsion systems, including internal combustion engines, electric motors, and batteries.
This role is ideal for a highly technical, research-oriented engineer who enjoys solving complex, open-ended problems. The team serves as a simulation and analysis resource for manufacturing engineering organizations, applying advanced modeling techniques to support manufacturing process development, troubleshooting, product validation, and future technology initiatives.
The successful candidate will combine strong engineering fundamentals, simulation expertise, intellectual curiosity, and a passion for solving challenging technical problems. This role is well-suited for engineers who thrive in environments with ambiguity, enjoy continuous learning, and are motivated by developing innovative solutions where established methods may not yet exist.
What You'll Do

• Partner with manufacturing, plant, product design, materials, and process engineering teams to define complex technical problems and analysis objectives.
• Conduct FEA, CFD, thermal, structural, and multiphysics analyses to identify root causes and develop practical solutions.
• Investigate heat treatment, material phase transformation, thermal gradients, residual stress, distortion, ductility, and other material and process behaviors.
• Apply simulation to manufacturing processes such as casting, machining, assembly, welding, and fluid flow.
• Develop analysis approaches independently, including selection of appropriate physics, assumptions, boundary conditions, material models, and solution methods.
• Perform research and literature reviews to support model development and technical recommendations.
• Create and improve analysis methods and workflows using tools such as Abaqus, Altair HyperWorks, STAR-CCM+, Dante, NX CAD, and Python.
• Automate preprocessing, solver execution, post-processing, and reporting where appropriate.
• Correlate simulation results with test, inspection, plant, experimental, or production data.
• Post-process and interpret results, prepare technical presentations, and communicate conclusions to internal customers and leadership.
• Provide technical guidance, train others, and mentor or coordinate the work of a small group of engineers as needed.

Your Skills & Abilities (Required Qualifications)

• Bachelor's degree in Mechanical Engineering, Materials Engineering, Manufacturing Engineering, or a related engineering discipline.
• Master's degree or PhD preferred.
• 3+ years of professional experience applying engineering simulation methods, including FEA, CFD, or related modeling tools, with 5+ years preferred.
• Experience developing, interpreting, validating, or applying engineering models to solve technical problems.
• Strong analytical and problem-solving skills.
• Ability to work independently in environments with incomplete information and evolving requirements.
• Strong technical communication and collaboration skills.

What Will Give You a Competitive Edge (Preferred Qualifications)

• Master's degree or PhD in Mechanical Engineering, Materials Engineering, Manufacturing Engineering, or related discipline.
• Experience with heat treatment simulation, metallurgy, phase transformation, distortion prediction, or material behavior analysis.
• Experience with computational fluid dynamics (CFD), heat transfer, or thermal analysis.
• Experience supporting manufacturing processes such as casting, machining, welding, assembly, electric motor production, battery manufacturing, or propulsion systems manufacturing.
• Experience validating simulations against experimental, inspection, plant, or production data.
• Familiarity with tools such as Abaqus, Altair HyperWorks, STAR-CCM+, Dante, NX, CAD software, Teamcenter, or similar platforms.
• Experience developing automation tools or analysis workflows using Python or other programming languages.
• Experience mentoring engineers or leading technical projects.

We recognize that strong candidates may not possess every preferred qualification listed above. If you have deep expertise in one simulation discipline and a demonstrated passion for solving complex technical problems, we encourage you to apply.
#LI-MH1
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 hybrid. This means the selected candidate is expected to report to a specific location at least 3 times a week {or other frequency dictated by their manager}.
The selected candidate will be required to travel <25% for this role.
Relocation benefits are available for candidates who qualify under company policy.
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.
Why Join Us
We believe we all must make a choice every day - individually and collectively - to drive meaningful change through our words, our deeds and our culture. Every day, we want every employee to feel they belong to one General Motors team.
Total Rewards | Benefits Overview
From day one, we're looking out for your well-being-at work and at home-so you can focus on realizing your ambitions. Learn how GM supports a rewarding career that rewards you personally by visiting Total Rewards resources.
Non-Discrimination and Equal Employment Opportunities (U.S.)
General Motors is committed to being a workplace that is not only free of unlawful discrimination, but one that genuinely fosters inclusion and belonging. We strongly believe that providing an inclusive workplace creates an environment in which our employees can thrive and develop better products for our customers.
All employment decisions are made on a non-discriminatory basis without regard to sex, race, color, national origin, citizenship status, religion, age, disability, pregnancy or maternity status, sexual orientation, gender identity, status as a veteran or protected veteran, or any other similarly protected status in accordance with federal, state and local laws.
We encourage interested candidates to review the key responsibilities and qualifications for each role and apply for any positions that match their skills and capabilities. Applicants in the recruitment process may be required, where applicable, to successfully complete a role-related assessment(s) and/or a pre-employment screening prior to beginning employment. To learn more, visit How we Hire.
Accommodations
General Motors offers opportunities to all job seekers including individuals with disabilities. If you need a reasonable accommodation to assist with your job search or application for employment, email us [email protected] or call us at 1-800-865-7580. In your email, please include a description of the specific accommodation you are requesting as well as the job title and requisition number of the position for which you are applying.