Industrial Engineer General Motors - Flint, Michigan Position Summary The Industrial Engineer serves as a technical leader responsible for driving operational excellence, productivity improvement, labor optimization, and continuous improvement initiatives within a high-volume automotive manufacturing environment. This role partners closely with production, maintenance, quality, manufacturing engineering, and plant leadership teams to improve safety, quality, delivery, cost, and employee engagement metrics. The Industrial Engineer develops and implements lean manufacturing strategies, standardized work systems, labor planning methodologies, ergonomic improvements, and workflow optimization solutions that enhance plant performance while supporting General Motors' Global Manufacturing System (GMS). The position also provides leadership, coaching, technical guidance to industrial engineering and continuous improvement personnel. Essential Responsibilities Lean Manufacturing Leadership
- Lead plant-wide continuous improvement initiatives using Lean Manufacturing principles.
- Drive waste elimination efforts focused on reducing non-value-added activities.
- Facilitate Kaizen events and rapid improvement workshops.
- Promote implementation of GM Global Manufacturing System (GMS) standards.
- Establish best practices for operational excellence across assigned production areas.
- Mentor engineers, supervisors, and production personnel on lean methodologies.
Productivity and Labor Optimization
- Analyze labor utilization and workforce efficiency.
- Develop staffing models based on production volume requirements.
- Improve operator work balance and workload distribution.
- Identify opportunities to reduce labor costs while maintaining safety and quality standards.
- Establish labor standards and performance measurement systems.
- Monitor and improve direct labor productivity metrics.
Time Study and Work Measurement
- Conduct detailed time studies and motion analysis.
- Develop standard work combinations and standardized work documentation.
- Utilize predetermined motion time systems and industrial engineering methodologies.
- Validate labor standards through direct observation and statistical analysis.
- Maintain engineering databases and labor performance records.
Process Design and Improvement
- Analyze manufacturing operations to identify bottlenecks and constraints.
- Design efficient workflows and material movement systems.
- Improve cycle times and reduce process variation.
- Support implementation of new equipment, tooling, and production technologies.
- Lead capacity planning and throughput optimization activities.
- Develop sustainable solutions that improve efficiency and reduce operating costs.
Facility and Workstation Design
- Create and maintain workstation layouts using AutoCAD, SolidWorks, or equivalent software.
- Perform manufacturing layout studies for new and existing production lines.
- Design workstation configurations that optimize operator productivity.
- Evaluate ergonomic risk factors and recommend improvements.
- Support facility modifications and production line reconfiguration projects.
Continuous Improvement and Cost Reduction
- Identify and execute projects that reduce manufacturing costs.
- Develop cost-benefit analyses for proposed improvements.
- Improve Overall Equipment Effectiveness (OEE) and plant productivity metrics.
- Reduce scrap, rework, downtime, and other operational losses.
- Monitor key performance indicators and implement corrective actions.
- Drive sustainable gains through process standardization.
Throughput and Bottleneck Analysis
- Analyze production constraints impacting vehicle output.
- Develop line balancing models to ensure efficient workflow.
- Lead bottleneck reduction activities.
- Support production launch and ramp-up activities.
- Participate in production trials and validation events.
- Ensure manufacturing systems support demand requirements.
Standardized Work Development
- Develop and maintain standardized work procedures.
- Train supervisors and operators on standardized work practices.
- Ensure process adherence and compliance with established standards.
- Implement visual management tools and performance tracking systems.
- Audit manufacturing processes for consistency and effectiveness.
Problem Solving and Root Cause Analysis
- Lead structured problem-solving initiatives.
- Utilize Lean Six Sigma methodologies and statistical analysis tools.
- Apply Root Cause Corrective Action (RCCA) processes.
- Support quality containment and corrective action implementation.
- Facilitate cross-functional investigations into safety, quality, and productivity concerns.
Cross-Functional Collaboration
- Partner with Production, Maintenance, Quality, Logistics, and Manufacturing Engineering departments.
- Support new vehicle launches, equipment installations, and capital projects.
- Participate in plant leadership reviews and operational planning meetings.
- Communicate project status, risks, and opportunities to stakeholders.
- Build strong relationships across all organizational levels.
Required Qualifications
- Bachelor's Degree in Industrial Engineering, Manufacturing Engineering, Mechanical Engineering, or related technical discipline.
- Significant experience in a manufacturing environment.
- Demonstrated success implementing Lean Manufacturing principles.
- Experience conducting time studies, work measurement, and motion analysis.
- Knowledge of standard work development and labor balancing techniques.
- Proficiency in AutoCAD, SolidWorks, or similar layout design software.
- Strong analytical and data interpretation skills.
- Ability to work effectively in a fast-paced production environment. [theladders.com]
Preferred Qualifications
- Lean Six Sigma Green Belt or Black Belt certification.
- Human Factors Engineering or Ergonomics experience.
- Automotive manufacturing experience.
- Experience with vehicle assembly, powertrain, or component manufacturing operations.
- Advanced statistical analysis capabilities.
- Knowledge of Industry 4.0 technologies and manufacturing analytics.
Strong Microsoft Excel, Power BI, and data visualization skills.