General Assembly 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:
The GA Process Engineer is responsible for defining, improving, and sustaining General Assembly manufacturing processes to safely deliver vehicles that meet all Safety, People, Quality, Responsiveness, Cost, and Environment (SPQRCE) objectives

What You'll Do:
1. Safety & People

• Ensure all GA processes, tools, and equipment comply with GM safety standards, legal requirements, and ergonomics criteria.
• Lead Safety Observation Tours (SOT) and close identified safety and ergonomic gaps in cooperation with Production, Safety, and Maintenance.
• Participate in risk assessments and Management of Change (MOC) for new or modified processes.
• Support operator training, certification, and skill upgrades for new processes, tools, and error-proofing devices.

• Define, document, and maintain GA process flows, workstation layouts, and standardized work for assigned zones (Trim / Chassis / Final / EOL, etc.).
• Develop and maintain Process Control Plans (PCP) , PFMEA , work instructions, and visual aids; ensure alignment with BIQ/GMS and GM global standards.
• Specify and validate GA tooling, fixtures, sub-assembly racks, WIP racks, special tools, and error-proofing devices to achieve safe and stable operations.
• Set and maintain process parameters and torque specifications; support annual torque and process audits where applicable.

• Lead GA process readiness for new programs, model year changes, and running changes from virtual build/PP builds through SORP and stabilization.
• Participate in simultaneous engineering with Product Engineering and central ME to assess manufacturability and process impact of design changes.
• Prepare and execute tryouts, pilots, and run-at-rate activities, ensuring process capability and BIQ compliance before volume ramp-up.
• Coordinate installation, commissioning, and buyoff of new GA equipment and tooling with Equipment/Automation teams and suppliers.

• Monitor GA KPIs (Safety, Scrap, Rework, DRR/DRL, Throughput, OEE, labor efficiency) and drive root-cause problem solving using structured methods (e.g., Red X, 5-Why, Fishbone).
• Identify and implement SPQRCE improvement projects (labor optimization, layout simplification, ergonomic improvements, quality robustness, material presentation).
• Lead or support GMS/BIQ assessments, process audits, and closure of gaps related to GA processes.
• Capture and deploy lessons learned and best practices across zones and programs.

• Work closely with Production, Quality, Maintenance, Facility, Material/Logistics, GPSC, Finance, SQE, IT and central/regional ME teams to ensure robust GA process performance.
• Provide technical support to maintenance for chronic equipment/process issues and to Quality for customer field issues and warranty reduction initiatives.
• Support supplier readiness reviews for GA-related components, tooling, and indirect materials where process impact is significant.

• Develop technical scope and basic requirements for GA process-related projects (capacity, quality, ergonomics, cost reduction).
• Support preparation of SOR, technical evaluations, and investment justifications for GA tooling and equipment.
• Ensure compliance with GM standards, local regulations, and documentation requirements (drawings, manuals, spare parts lists, calibration, ILM where applicable).

• Bachelor's degree in Mechanical, Production, Mechatronics, or Automotive Engineering (or equivalent technical discipline).
• 4 ~ 6 years of experience in automotive General Assembly or vehicle manufacturing environment (Process, Production, Quality, or ME) preferred.
• Demonstrated involvement in process development, launch, or significant process improvement projects.

• Strong knowledge of GA assembly processes, station tooling, fixtures, and ergonomics principles.
• Working knowledge of PFMEA, PCP, BIQ, GMS, and structured problem-solving methodologies.
• Ability to read and interpret engineering drawings, 3D models, and product specifications (GD&T awareness preferred).
• Proficient in common engineering and office tools (e.g., AutoCAD/plant layout tools, Excel, PowerPoint, Teams, etc.).
• Familiarity with torque systems, error-proofing, and EOL test systems is an advantage.

• High level of ownership, initiative, and analytical ability in complex manufacturing situations.
• Strong communication and interpersonal skills; able to work effectively with cross-functional and hourly teams.
• Organized and able to manage multiple initiatives and priorities in a fast-paced production environment.
• Passion for safety, quality, and continuous improvement in manufacturing operations.