Body Shop Process Engineer

Description

Work Arrangement: This role is categorized as onsite. this means the successful candidate to report to the GM office full time.

The Role:
Body Shop Process Engineer is responsible for defining, improving, and sustaining body-in-white (BIW) manufacturing processes (welding, framing, respot, hemming, sealer, and sub-assembly) to safely deliver dimensionally robust bodies that meet all Safety, People, Quality, Responsiveness, Cost, and Environment (SPQRCE) objectives.

What You'll Do:
1. Safety & People

• Ensure all body shop cells, fixtures, robots, weld guns, and material handling devices comply with GM safety, lockout, and ergonomics standards and local regulations.
• Lead Safety Observation Tours (SOT) and ergonomics assessments in weld, framing, and hemming areas; develop and execute action plans to close identified gaps.
• Lead/participate in risk assessments and Management of Change (MOC) for new or modified body shop processes and equipment.
• Support operator and skilled trades training, certification, and upskilling on new body fixtures, robots, weld guns, sealer systems, and error-proofing devices.

• Define, document, and maintain body shop process flows, line balancing, and workstation layouts for body sides, underbody, framing gates, respot stations, closures, and hemming cells.
• Develop and maintain PFMEA , Process Control Plans (PCP) , JES/standardized work, and visual aids for all assigned operations; ensure alignment with BIQ/GMS and GM global body standards.
• Manage and release Body Shop PCP and PFMEA gap closure actions in coordination with Quality and Dimensional teams.
• Specify, validate, and sustain body shop tooling and equipment: weld and framing fixtures, grippers, clamps, guns, sealer nozzles, and gauges to ensure safe, capable, and maintainable operations.
• Define and maintain weld schedules, sealer patterns, clamp plans, and process parameters, ensuring traceability and change control.

• Own dimensional performance of assigned zones in partnership with Dimensional Quality & VAA SME and plant Dimensional/VDQM teams (A-rate/C-rate, GSQE, BIQ metrics).
• Support definition and execution of dimensional measurement strategies using TAC fixtures, CMM, laser scanning, and vision systems in cooperation with central BIW/Measurement Systems teams.
• Analyze dimensional data, identify root causes (fixture, tooling, method, product), and implement robust corrective actions to stabilize body geometry.
• Support weld destruct, nugget size, sealer quality, and other body shop quality checks; ensure results are reflected in PFMEA/PCP and standardized work.

• Lead body shop process readiness for new programs, model year changes, and running changes from early trials through SORP and stabilization.
• Participate in simultaneous engineering with Product Engineering, central ME, Dimensional, and suppliers to assess manufacturability of new body structures and closures, and to protect body shop process capability.
• Plan and execute body shop tryouts, pilot builds, slow builds, and run-at-rate events, ensuring safety, dimensional capability, throughput, and BIQ compliance before volume ramp-up.
• Coordinate installation, commissioning, and buyoff of new body fixtures, robots, and automation with Equipment/Automation teams and suppliers, including runoff and final acceptance documentation.

• Monitor body shop KPIs (Safety, scrap, rework, A-rate/C-rate, downtime, throughput, OEE, indirect material usage) and drive structured root-cause problem solving (e.g., Red X, 8D, 5-Why).
• Identify and implement SPQRCE improvement projects (cycle time reduction, robot optimization, layout simplification, fixture robustness, indirect material and energy reduction).
• Capture and deploy lessons learned and best practices across body shop zones and future programs in cooperation with regional and global ME teams.

• Work closely with Production, Quality, Maintenance, Facility, Dimensional, GA, Paint, Material/Logistics, GPSC, Finance, SQE, Projects, GMS and regional ME teams to ensure robust body shop performance and launch readiness.
• Provide technical support to Maintenance for chronic tooling, fixture, and automation issues (weld guns, robots, clamps, sealer systems) to minimize downtime and improve maintainability.
• Interface with tooling and automation suppliers for new equipment, modifications, and problem resolution; ensure adherence to GM body, safety, and automation standards.
• When applicable, support VAA (Value-Added Assembler) projects on body-related tooling and dimensional topics with Dimensional & VAA SME.

• Bachelor's degree in Mechanical, Production, Mechatronics, or Automotive Engineering (or equivalent technical discipline).
• 3 ~ 5 years of experience in Body Shop / BIW manufacturing or welding/automation within automotive or similar industry preferred.
• Demonstrated experience in process development, launch, or major improvement projects in a highly automated body shop is an advantage.

• Strong knowledge of body-in-white manufacturing processes, including spot/MIG/laser welding, hemming, framing, respot, and sealer application.
• Understanding of dimensional quality, GD&T, and body measurement systems (TAC fixtures, CMM, laser scanning, vision guidance).
• Working knowledge of PFMEA, PCP, BIQ, GMS, and structured problem-solving methodologies in a manufacturing environment.
• Ability to read and interpret product and tooling drawings, 3D models, and process documentation; familiarity with Teamcenter/plant layout tools is preferred.
• Proficient in standard office and engineering tools (e.g., Excel, PowerPoint, Teams, basic CAD).
• Root cause analysis (5 Whys, Fishbone, A3 problem solving)
• Continuous Improvement (CI) project evaluation and benefit tracking.
• Microsoft Office & Power Apps.

• High level of analytical ability and problem-solving skills for unusual and complex manufacturing and dimensional issues.
• Strong communication and interpersonal skills; able to lead discussions with cross-functional teams, shop-floor personnel, and suppliers.
• Organized, self-motivated, and able to manage multiple projects and daily operational support in a fast-paced production environment.
• Demonstrated drive for results, ownership, and commitment to safety, quality, and continuous improvement in manufacturing operations.