Sr. Quality Assurance Engineer at General Motors in Flint, Michigan, United States of America

Job description

• We are seeking a quality-focused and collaborative Sr. Quality Assurance Engineer to join the GPS engine manufacturing team at Flint Engine Operations. This role is responsible for protecting customer requirements, improving product and process quality, and driving disciplined problem solving across engine assembly and related manufacturing operations.
• The successful candidate will work closely with production, manufacturing engineering, program/product engineering, supplier quality, maintenance, and plant leadership to prevent defects, resolve quality issues, and sustain robust process controls. The role requires a hands-on presence on the production floor, strong analytical thinking, and the ability to make timely, fact-based decisions in a high-volume manufacturing environment.

Responsibilities

• Support monitoring of engine quality performance using key metrics such as FTQ, IPPM, scrap, rework, audit findings, customer complaints, and warranty trends.
• Facilitate structured problem solving via the Fast Response process, using tools such as Red X, 5 Whys, Fishbone analysis, fault-tree analysis, and data-based process investigation.
• Manage and perform internal audits, issue corrective action reports and validate/monitor responsiveness.
• Partner with production and manufacturing engineering to improve standardized work, error-proofing, inspection methods, reaction plans, and process controls.
• Review and maintain quality documentation, including control plans, process flow documentation, standardized work, PFMEA inputs, inspection plans, layered audit results, and corrective action records.
• Support APQP, PPAP, launch readiness, engineering changes, process changes, and new-product or major-equipment introductions.
• Perform quality audits and layered process assessments, identify systemic gaps, and track actions to closure.
• Analyze trends and recurring issues to identify opportunities for defect prevention and variation reduction.
• Manage internal share point sites in support of proper documentation management.
• Support Business Plan Deployment process.
• Communicate quality risks, priorities, and escalation needs to plant leadership and cross-functional stakeholders.
• Participate in daily production meetings, quality reviews, launch meetings, and cross-functional problem-solving activities.
• Maintain accurate records and ensure quality actions are completed on time and sustained.
• Manage the global quality requirements workflow process and any applicable deviations.
• Function as the GSIP administrator for the plant.
• Potential to function as the ILM coordinator for the plant.
• Support GMS BIQ statement implementation: manage BIQ training for the Quality team, SME for specific BIQ statements.
• Manage the Bypass process documentation.
• Manage the Repair procedure approval documentation.
• Present quality information as applicable to plant leadership.
• Demonstrate customer focus, managerial courage, and ownership of results in all quality decisions.

Requirements

• Bachelor’s degree in engineering, quality, or a related technical field (or equivalent
• experience).
• 5 years of experience in quality, manufacturing, engineering, or a related technical discipline.
• Experience with root-cause analysis, corrective action, and structured problem-solving methods.
• General knowledge of engine or automotive manufacturing processes and quality systems.
• Ability to read and interpret engineering prints and perform or coordinate basic part and feature measurement.
• Ability to work effectively with production employees, engineers, suppliers, and plant leadership.
• Willingness to work hands-on in a manufacturing environment and spend substantial time on the production floor.
• Ability to work off-shift and over time as needed.
• 5+ years of experience in quality, manufacturing, engineering, or a related technical discipline.
• Previous experience in engine manufacturing, powertrain, or automotive quality assurance.
• Familiarity with APQP, PPAP, launch readiness, control plans, PFMEA, and layered process audits.
• Experience with machining, casting, assembly, electrical, or engine-component manufacturing processes.
• Experience using Red X or other GM structured problem-solving methodologies.
• Experience investigating warranty, field, or customer-returned product issues.
• Hands-on experience with quality audits, measurement systems, and inspection plans.
• Experience supporting engineering changes, process changes, and new equipment launches.
• Knowledge of continuous-improvement methods and defect-prevention techniques.
• Demonstrated ability to manage multiple priorities in a fast-paced manufacturing environment.

Skills

Required

• Root-cause analysis
• Corrective action
• Structured problem-solving methods
• Quality systems
• Read and interpret engineering prints
• Hands-on in manufacturing environment
• Work off-shift and over time

Preferred

• APQP
• PPAP
• Launch readiness
• Control plans
• PFMEA
• Layered process audits
• Continuous-improvement methods
• Defect-prevention techniques

Benefits

• This job may be eligible for relocation benefits.