Cost Engineer - Battery Pack Structure & Propulsion Benchmarking Lead

Description

Responsible for developing cost models, cost estimates, and competitive benchmarking for battery pack structures across EV, PHEV, and HEV propulsion systems. This role serves a dual function: acting as the execution cost engineer for battery pack structural assemblies and as the cost benchmarking lead for the entire propulsion system cost intelligence across GM's electrification programs. The mission is to drive cost out of EV propulsion by building deep, data-grounded cost knowledge.

This role requires a strong foundation in metal manufacturing processes - including stamping, die casting, extrusion, welding, and roll forming - combined with the ability to translate that manufacturing understanding into rigorous, part-level cost models. The selected candidate will collaborate closely with the Battery Pack Engineering team, Propulsion Benchmarking team, Propulsion Purchasing, Vehicle Program teams, global JV partners, and the supply base to guide cost-competitive design decisions and support negotiations.

This position requires a high degree of independent judgment, initiative, and management of multiple assignments, all focused on delivering accurate cost estimates and credible cost reduction opportunities.

Responsibilities

• Lead propulsion cost benchmarking efforts for propulsion systems - across BEV, PHEV, and HEV architectures
• Develop ground-up cost models for battery pack structural assemblies using CAD models, drawings, teardown content, outline sketches, and supplier benchmarking data; leverage tools including GMCO$T / Siemens Teamcenter PCM
• Cost EV, PHEV, and HEV battery pack structures with particular focus on material-intensive components (aluminum die castings, stampings, extrusions, roll-formed profiles, friction-stir welds, structural adhesives)
• Conduct competitive teardown and benchmarking of pack structures from leading OEMs (Tesla, BYD, Hyundai, etc.) to develop cost intelligence and identify best-in-class design-to-cost practices
• Support cost targets and allowable cost development - prepare and present material for DDRs, ACRs, PSRs, and program cost reviews; set and defend cost targets with engineering and purchasing stakeholders
• Partner with Purchasing during supplier quote reviews and negotiations; provide cost-based substantiation to support commercially disciplined outcomes
• Research raw material pricing (aluminum, steel, copper, polymer composites), manufacturing process benchmarks, capital investment norms, and emerging trends (e.g., gigacasting, friction stir welding, structural battery integration)
• Identify and recommend cost reduction opportunities based on benchmarking insights, design alternatives, manufacturing process improvements, and supply chain options
• Mentor and support broader electrification cost engineering team members; share knowledge of metal manufacturing cost structures and battery pack assembly processes
• Travel to supplier facilities and benchmarking centers as needed to grow cost knowledge and provide hands-on costing support

• Knowledge of metal manufacturing processes applied to battery pack structures, including but not limited to: aluminum high-pressure die casting (HPDC), stamping and sheet metal forming, aluminum extrusion, roll forming, MIG/laser/friction-stir welding, structural bonding, and mechanical fastening
• Ability to develop cost models for structural battery pack components using part drawings, CAD geometry, process assumptions, and benchmarking data
• Experience with battery pack structures for EV, PHEV, and/or HEV vehicles - including familiarity with pack enclosure architecture, thermal management integration, module mounting strategies, and sealing systems
• Practical experience in cost benchmarking, teardown analysis, manufacturing plant visits, or cost reduction workshops in a propulsion or body-in-white / metal manufacturing context
• Strong analytical skills - able to dive into complex data sets without losing sight of the business picture; capable of translating manufacturing process detail into clear, defensible cost estimates
• Cross-functional collaboration skills - comfortable working with engineers, purchasing managers, program leads, and supplier counterparts; able to influence without direct authority
• Excellent communication skills - written and verbal; able to present cost data, business cases, and cost reduction recommendations to leadership
• Proficiency in software & systems such as MS Office, with emphasis on Excel for cost modeling; Power BI and data analytics tools; familiarity with GMCO$T or Siemens Teamcenter Product Cost Management preferred
• Self-motivated, goal-oriented, and results-driven - capable of managing multiple assignments with a high degree of autonomy ### Preferred Qualifications
• Metal manufacturing industry background - prior experience in a stamping, die casting, extrusion, BIW tooling, or fabrication manufacturing environment strongly preferred
• Prior work in Body-in-White (BIW) processing, tooling, or die/press room operations provides direct transferable knowledge of aluminum and steel forming costs applicable to battery pack enclosures
• Experience in conducting cost studies at manufacturing plants
• Familiarity with global cost structures (North America, Europe, China) and OEM vs. Tier supplier cost dynamics
• Graduate degree in Engineering, Manufacturing, Supply Chain, or Business
• Experience with gigacasting or structural battery pack cost analysis a plus ### Education
• Bachelor's degree required in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or a related technical field
• At least 3-5 years of relevant experience in automotive manufacturing, cost engineering, product design/engineering, or purchasing; experience specifically in metal-forming or battery pack manufacturing environments highly valued