Job Title: General Assembly Manufacturing Engineer
Location: Warsaw, Indiana
Level: Senior
Client Facing: Yes
About PAC Group
At The PAC Group (PAC), we specialize in engineering consulting, program management, and operational excellence—delivering high-impact solutions in more than 20 countries. We’re proud to partner with the world’s leading companies in automotive, aerospace, industrial, and technology sectors, providing strategic guidance and hands-on execution that drive innovation and efficiency. Whether we’re launching advanced manufacturing systems, deploying digital simulation tools, or scaling global operations, PAC thrives at the intersection of technology, engineering, and problem-solving.
Joining PAC means joining a dynamic, fast-paced, and global team that values curiosity, collaboration, and continuous improvement.
Role Purpose
The General Assembly Manufacturing Engineer is the architectural lead for the production environment. Responsible for transforming complex product designs into scalable, high-efficiency manufacturing realities. From initial concept through Final Vehicle Assembly, the engineer owns the launch strategy, validate automated workflows, and bridge the gap between Design Engineering and the factory floor to ensure a flawless start of production.
Key Responsibilities
- Program Launch & Manufacturing Readiness: Establish comprehensive production schedules and pre-build sequences. Manage detailed build plans to ensure all manufacturing processes are primed for on-time delivery.
- Process Development & Validation: Design and validate GA workflows, including tooling specifications and automation integration. Conduct PFMEAs, establish control plan standards, and ensure 100% compliance with quality benchmarks.
- Cross-Functional Coordination: Act as the primary technical interface between Engineering, Manufacturing, and Quality. Lead DFM/DFMA (Design for Manufacturing/Assembly) reviews and collaborate with Supply Chain to ensure material readiness.
- Cost & Efficiency Management: Execute cost-reduction initiatives and manage CAPEX for tooling and equipment. Deliver financial analyses (labor, materials, overhead) to protect profitability.
- Risk Management & Issue Resolution: Identify manufacturing risks early through rigorous assessments. Provide root cause analysis and corrective actions during the launch phase, escalating critical roadblocks to leadership.
- KPI Tracking & Reporting: Track and report on KPIs, including PPAP completion, OEE (Overall Equipment Effectiveness), scrap rates, and throughput status.
Required Qualifications
- Bachelor’s degree in Mechanical, Manufacturing, or Industrial Engineering (or a related technical field).
- Experience: 5+ years of experience in high-volume manufacturing (Automotive, Aerospace, or Heavy Machinery preferred).
- Proven experience with Process Sheets and PFMEA development, Control Plans, and Lean Manufacturing principles.
- Project Management: Demonstrated ability to manage complex launch schedules, CAPEX budgets, and vendor relationships.
- Strong interpersonal skills with the ability to lead cross-functional technical reviews (DFM/DFMA).
- Familiarity with procurement processes: RFQs (Request for Quotes), design review, and vendor buyoffs.
- Skills in managing large-scale capital equipment projects from inception to launch.
- Ability to provide immediate, on-floor issue resolution during critical build phases.
- Interfacing effectively with different stakeholders, including design engineers, production teams, and outside vendors.
- Exceptional verbal and written skills for authoring specifications and presenting technical status updates.
- Ability to perform under pressure during high-stakes "launch phases" and adjust to changing build requirements.
Preferred Qualifications
- Expertise in power tool specification, installation, and torque validation.
- Technical proficiency in DTC (Diagnostic Trouble Code) analysis.
- Proficiency in CAD software for design reviews and layout planning.
- Proficiency in data visualization tools (Tableau/PowerBI) for monitoring OEE and scrap rates.
- Hands-on experience with robotics, PLC logic, or automated conveyance systems within General Assembly.
- Six Sigma Green or Black Belt certification.
The salary range for this position is dependent upon experience, education, and qualifications.
Pay Range: $105,000 USD - $120,000 USD
