Casting Process Engineer

Job Description

Casting Process Engineer – Development Program | General Motors

The Tone:
This is a full-time, onsite role for General Motors, located at Bedford, Defiance, or Saginaw Foundry. General Motors is a global automotive company with a vision for Zero Crashes, Zero Emissions, and Zero Congestion, embracing the responsibility to lead meaningful change. This two-year developmental program is crucial for accelerating technical expertise in casting manufacturing, expanding enterprise casting knowledge, and deepening understanding of GM’s manufacturing systems and operations. The role contributes to the development, testing, and implementation of new casting programs, platforms, and technology within the company.

The TL;DR
• Role: Early Career
• Type: Full-time
• Location: In-person Bedford, Defiance, or Saginaw Foundry

• Team: Casting/Manufacturing Engineering team reporting to the Process Engineering Team
• Mission: Develop and validate casting manufacturing projects by following a systematic engineering process to support production launch and processing.
• Tech Stack: Magma, Flow 3D, NX, Catia, QS-Stat, Flexnet, CMM, x-ray, CT

What You’ll Actually Do
• Program Support: Collaborate with various GM technical groups and external partners to support launch processes via manufacturing validations, build plans, and PPAP.
• Process Development: Develop manufacturing processes, equipment, tooling, alternatives, sequences, and operations to efficiently produce castings.
• Analysis & Optimization: Lead the analysis of casting defects, analyze first-time quality data, and optimize processes using statistical tools like DOE and DFSS green belt.
• Testing & Implementation: Support the testing and installation of equipment, tooling, and technologies, as well as assist in troubleshooting and implementing process improvements both on and off-site.
• Documentation & Controls: Develop essential process documentation, including Process flow diagrams, Control plans, PFMEA, and standard work documents, and manage Process Controls plans using specified software.

The Must-Haves
• Background: Pursuit of a Bachelor’s or Master’s degree in Manufacturing Engineering, Mechanical Engineering, Material Science, Industrial Engineering, Engineering Technology, or Metallurgy.
• Experience: Must be graduating between May 2025 and December 2026. Able to work full-time (40 hours per week) with required overtime and willing to work in a plant environment.
• Skills: Ability to work on a shop floor, hands-on equipment experience, analysis of casting defects, data analysis using DOE/DFSS green belt, and performing non-destructive/destructive testing procedures (e.g., CMM, leak testing, x-ray).
• Bonus: Experience in a plant environment or similar, training in foundry processes or process engineering procedures, basic knowledge of Magma, Flow 3D, NX, Catia, or any 3D design software, and degree courses with a metal casting focus.