Job 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.

2. Process Design, Documentation & Control

• 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.

3. Dimensional & Quality Performance

• 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.

4. Launch & Engineering Changes

• 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.

5. Continuous Improvement & Problem Solving

• 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.

6. Cross-Functional & External Interfaces

• 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.

Your Skills & Abilities (Required Qualification)
Educational and Experience Background:

• 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.

Technical Skills:

• 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.

Competencies:

• 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.

About GM

Our vision is a world with Zero Crashes, Zero Emissions and Zero Congestion and we embrace the responsibility to lead the change that will make our world better, safer and more equitable for all.

Why Join Us

We believe we all must make a choice every day – individually and collectively – to drive meaningful change through our words, our deeds and our culture. Every day, we want every employee to feel they belong to one General Motors team.

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General Motors is committed to being a workplace that is not only free of unlawful discrimination, but one that genuinely fosters inclusion and belonging. We strongly believe that providing an inclusive workplace creates an environment in which our employees can thrive and develop better products for our customers.

We encourage interested candidates to review the key responsibilities and qualifications for each role and apply for any positions that match their skills and capabilities. Applicants in the recruitment process may be required, where applicable, to successfully complete a role-related assessment(s) and/or a pre-employment screening prior to beginning employment. To learn more, visit How we Hire

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