Senior Manufacturing Engineer – Crankshaft Execution

Job description

Job Description At General Motors, our product teams are redefining mobility. Through a human-centered design process, we create vehicles and experiences designed not only to be seen, but also to be felt. From breakthrough hardware and battery systems to intuitive design, intelligent software, and next-generation safety and entertainment features, we are turning today’s impossible into tomorrow’s standard. Every day, our products move millions of people as we work to make driving safer, smarter, and more connected—shaping the future of transportation on a global scale. Flint Engine Operations is seeking an execution-focused Manufacturing Engineer to lead the crankshaft machining line and deliver a safe, reliable, high-quality process that supports sustained engine production. You will lead execution through the later stages of program launch, transitioning the line from installation and qualification through PPAP, process stabilization, plant readiness, ramp-up, and operational handoff. This role partners closely with upstream engine machining, downstream engine assembly, Product Engineering, Central Office Manufacturing Engineering, OEMs, contractors, and plant operations. What You’ll Do Launch Execution and Ramp-Up Lead crankshaft line execution from installation and qualification through PPAP, SORP, ramp-up, and operational handoff. Drive throughput toward purchased line rate and Lean Capacity Rate while protecting safety, quality, and uptime. Own launch deliverables and drive closure of tooling, gaging, control plan, error-proofing, and equipment issues. Lead OEM and contractor issue reviews, escalate risks, and coordinate Program Audits and Red/Yellow/Green Tag signoffs. Maintain 30- and 60-day look-ahead reports and Launch Wall updates. Process and Documentation Ownership Align Program, Engineering, Manufacturing, engine machining, and engine assembly teams to achieve plant readiness. Maintain job instructions, PFMEAs, control plans, picture process sheets, machine drawings, and tooling drawings. Manage OEM safety requirements, including training, pre-task planning, and safety observation tours. Sustain launch deliverables through SORP and for six months afterward. Machining and Equipment Execution Support installation, debugging, run-off, and optimization across crankshaft turning, milling, drilling, induction hardening, grinding, polishing, balancing, washing, and gauging processes. Lead or participate in Machine Run-Off activities at OEM and GM sites. Conduct or validate Safety Risk Assessments for new and rebuilt equipment. Apply QS-Stat, Red X, DOE, DFSS, and other structured problem-solving methods to improve quality, capability, cycle time, and cost. GD&T, Measurement, and Quality Interpret crankshaft prints and apply GD&T, datums, feature control frames, and tolerance stack-ups to resolve dimensional issues. Partner with CMM and gaging engineers to validate measurement systems, resolve correlation issues, and approve critical-feature measurement methods. Support closure of cleanliness and other product-critical requirements. Improve PFMEAs and control plans to strengthen process consistency and reduce warranty risk. Continuous Improvement and Team Development Apply launch lessons learned through BOE/BOP updates and read-across to future programs and sites. Drive Launch Scorecard, First Time Quality, On-Time Delivery, HPU, headcount, and cost-per-unit objectives. Mentor less-experienced engineers and strengthen team capability. Required Qualifications Bachelor’s degree in Mechanical, Manufacturing, Industrial Engineering, or a related field, or equivalent manufacturing experience. At least five years of total professional experience. One to three years of crankshaft or comparable rotating-component machining launch experience, including direct exposure to PPAP, qualification, and ramp-up execution. Strong GD&T knowledge and the ability to interpret part prints and translate design intent into process and gaging decisions. Working knowledge of dimensional measurement systems, including CMM, hard gaging, or equivalent technologies. Demonstrated experience with data-driven problem-solving and root-cause analysis. Ability to teach others and support team capability growth. Strong written and verbal communication skills, including the ability to clearly escalate issues and align engineering, operations, and OEM partners. Willingness to work flexible hours and shifts, including temporary off-shift, holiday, and weekend support for qualification runs, PPAP, and ramp-up activities. Preferred Qualifications Experience completing a full PPAP-to-ramp-up cycle on a crankshaft or other rotating-component machining line. Experience with turning, grinding, induction hardening, balancing, or related machining processes. Machine Run-Off experience at OEM sites. CMM programming or gage design validation experience, such as Zeiss Calypso or equivalent. Familiarity with PFMEAs, Control Plans, and error-proofing methodologies. Experience managing launch deliverables, Master Dot tracking, or Launch Wall reporting. Engine machining, engine assembly, or high-volume manufacturing experience. Experience working with Agile methodologies, including Scrum and sprint frameworks. Knowledge of Global Manufacturing System principles and workplace safety systems. Six Sigma, Red X, or other structured problem-solving certification. Previous GM Manufacturing Engineering experience supporting an engine or propulsion systems program. Work Environment and Travel This is a full-time, onsite position at Flint Engine Operations. Daily presence on the crankshaft machining floor is required during PPAP and ramp-up, along with regular coordination with engine machining and engine assembly teams. Approximately 25%–50% travel may be required for OEM run-offs, supplier visits, cross-site learning, networking, and new crankshaft site launches. Flexibility to provide temporary off-shift, holiday, and weekend support is expe