Senior Manufacturing Engineer Gears

Sponsorship : GM DOES NOT PROVIDE IMMIGRATION-RELATED SPONSORSHIP FOR THIS ROLE. DO NOT APPLY FOR THIS ROLE IF YOU WILL NEED GM IMMIGRATION SPONSORSHIP (e.g., H-1B, TN, STEM OPT, etc.) NOW OR IN THE FUTURE.

Work Arrangement​​: This role is categorized as onsite. This means the successful candidate is expected to report to Grand Rapids Operations on a full-time basis.

The successful candidate must have availability to work any shift; overtime and some weekends are expected.

The Role:

As a Senior Gear Manufacturing Engineer, you will:

• Serve as a Subject Matter Expert (SME) for hypoid gear manufacturing, providing technical leadership and hands-on expertise in gear quality, process optimization, troubleshooting, root cause analysis, corrective actions, and continuous improvement across high-volume machining operations.
• Develop, maintain and train teams on standard work, setup sheets, tooling lists and cell documentation for hypoid gear production.
• Collaborate with Product Engineering, Quality, and Original Equipment Manufacturers (OEMs) on product designs for continuous improvements activities.
• Mentor and coach manufacturing engineers and production personnel; transfer knowledge to sustain continuous improvements and reduce process variation with process documentation and document control.
• Build and sustain a good working relationship between hypoid gear manufacturing and axle assembly teams to improve quality and manufacturing uptime.

What You’ll Do:

Responsible for supporting activities that may include:

• Provide day-to-day technical leadership and support for manufacturing operations, maintenance, and CNC machining processes.
• Serve as a technical resource for gear quality standards and support Global Manufacturing Systems (GMS) initiatives across multiple departments.
• Drive safety, quality, throughput, and equipment efficiency improvements through root cause analysis, problem solving, lean manufacturing principles, and continuous improvement activities.
• Develop, implement, and sustain process improvements, innovative technologies, and manufacturing solutions that enhance operational performance and reduce variation.
• Lead cross-functional efforts to resolve quality, process, equipment, and reliability issues while supporting production schedules and product requirements.
• Provide technical direction and oversight for internal teams, contractors, vendors, and external resources supporting manufacturing and maintenance.
• Develop, maintain, and ensure accuracy of manufacturing technical documentation, standard work, and training materials; facilitate training for engineering, production, and maintenance personnel.
• Plan, coordinate, and execute projects to meet timing, budget, and operational objectives.
• Evaluate and recommend capital equipment investments, emerging technologies, and business cases to improve efficiency and reduce structural costs.

Your Skills & Abilities (Required Qualifications)​​:

• Bachelor of Science degree in Engineering or equivalent experience
• 5+ years of experience in engineering support role in a CNC machining environment (hypoid gears preferred)
• Deep working knowledge and practical experience with grinding, lapping, shot peening, and gear metrology equipment and capability processes.
• Previous experience with computer- based office and engineering software, including Microsoft Office and AutoCAD
• Ability to work weekends and overtime as needed

What Will Give You A Competitive Edge (Preferred Qualifications):​

• Proven ability to interface with gear OEMs and machine tool builders to evaluate new technology, tooling trials, cost of ownership analyses and manufacturability improvements.
• Advanced understanding of hypoid gear geometry corrections with gear CMM reports, and tooth-contact pattern adjustments via machine-setting.
• Experience with SolidWorks
• Formal problem-solving training/experience (RedX, 8D, Six Sigma, etc)

This role may be eligible for relocation benefits.