Job Description
General Motors' Global Manufacturing Engineering team is seeking a Project Engineer to support the physics-based emulation and simulation initiative. In our pursuit of Zero Crashes, Zero Emissions, and Zero Congestion, this role is central to reinventing how we design, validate, and commission stamping press equipment, replacing costly physical trials with high-fidelity virtual environments.
Reporting to the Project Manager, you will serve as the primary technical contributor for the physics-based digital twin and virtual commissioning platform for GM's North American press shop stamping operations, spanning front-of-line blanking through end-of-line transfer, and will act as a subject matter expert on simulation and emulation activities across the project.
What You'll Do
Project Coordination & Technical Support
Support the Project Manager in tracking scope, schedule, and open-item registers; maintain up-to-date PDCA logs for assigned simulation deliverables
Coordinate with suppliers (e.g., Ansys, Schuler/DigiSim), plant teams (@Marion), die engineering, and controls engineering to integrate simulation results into program execution
Participate in and provide technical input for design reviews and virtual commissioning sign-off sessions
Communicate technical findings, simulation results, and open issues to the Project Manager and cross-functional stakeholders
Travel to supplier sites and stamping plants to support integration and commissioning activities
Physics-Based Simulation & Digital Twin Development
Develop and maintain high-fidelity 3D simulation models of stamping press lines, including press mechanics, die interfaces, automation tooling, and material handling systems
Build and manage digital twin environments representing full press line behavior; kinematics, motion/interference curves, servo drives, and cam sequencing
Conduct steady-state and dynamic simulations, "what-if" scenario analyses, and bottleneck/throughput studies to optimize press line performance
Validate simulation models against real plant performance data (SPM, ICR, downtime records) and continuously improve model fidelity
Develop and maintain the press model library (PLMaker, PLAdmin, PLS) and manage press model updates within simulation software platforms
Virtual Commissioning & Controls Integration
Establish and maintain virtual commissioning environments for PLC, HMI, and robot program validation prior to physical implementation
Perform software-in-loop (SIL) and hardware-in-loop (HIL) testing for automation and controls systems
Integrate simulation environments with control platforms (Rockwell, Siemens TIA Portal, Beckhoff TwinCAT) and industrial communication protocols
Support controls engineers and automation suppliers in validating press-to-die interface logic, part transfer systems, and safety interlock behavior
Die Engineering & Process Optimization
Apply deep understanding of die-to-press and die-to-tooling interactions to build accurate simulation boundary conditions
Collaborate with die designers and die execution engineers at NAETC to validate process plans prior to physical die build
Analyze simulation outputs to identify collisions, interference conditions, throughput bottlenecks, and process improvement opportunities
Conduct 90-day post-SORP performance reviews to validate simulation predictions against production launch outcomes
Identify and communicate product and manufacturing requirement (MR) criteria that affect simulated throughput
Platform Administration & Knowledge Management
Act as subject matter expert for simulation tools including PLS, Process Simulate, DigiSim, NX, EDWS, and Teamcenter
Develop and maintain simulation training materials and standardized work procedures for the simulation engineering team
Manage license server infrastructure and software deployment for the simulation platform (including GM VM environments)
Evaluate and recommend commercially available simulation tools and technologies to continuously advance platform capabilities
Compensation Starting At: $50/hr. Exact compensation may vary based on several factors, including skills, experience, and education. Benefit packages for this role will start on the 31st day of employment and include medical, dental, and vision insurance, as well as HSA, FSA, and DCFSA account options, and 401k retirement account access with employer matching. Employees in this role are also entitled to paid sick leave and/or other paid time off as provided by applicable law.
We are a company committed to creating diverse and inclusive environments where people can bring their full, authentic selves to work every day. We are an equal opportunity/affirmative action employer that believes everyone matters. Qualified candidates will receive consideration for employment regardless of their race, color, ethnicity, religion, sex (including pregnancy), sexual orientation, gender identity and expression, marital status, national origin, ancestry, genetic factors, age, disability, protected veteran status, military or uniformed service member status, or any other status or characteristic protected by applicable laws, regulations, and ordinances. If you need assistance and/or a reasonable accommodation due to a disability during the application or recruiting process, please send a request to [email protected] learn more about how we collect, keep, and process your private information, please review Insight Global's Workforce Privacy Policy: https://insightglobal.com/workforce-privacy-policy/.
Skills and Requirements
3+ years of experience physics-based Simulation Ansys, iPhysics, Emulate3D, WinMOD, EKS, or equivalent
Experience in manufacturing / industrial background - Ideally stamping or press simulation
Digital twin experience Stamping background
Background in virtual commissioning environments and hardware-in-loop testing
Programming experience in Python, C#, or MATLAB for simulation workflow automation and data analysis
Experience with industrial network protocols (EtherCAT, Ethernet/IP, PROFINET, OPC UA)
Familiarity with Model-Based Systems Engineering (SysML)
Knowledge of safety systems and industrial standards (ISO, OSHA)
Experience with Eplan electrical design software
Familiarity with Agile/Jira/Confluence project management environments
