Senior Manufacturing Engineer - General Assembly

Job Title: Senior Manufacturing Engineer / Manufacturing Engineering Manager - General Assembly (GA)

Location: California

Level: Senior / Manager

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:

Lead the definition, development, and industrialization of General Assembly processes to enable efficient vehicle build, ergonomic operations, quality performance, and scalable production for a new vehicle program and greenfield manufacturing facility. This role is critical in supporting early manufacturing readiness, influencing facility and investment decisions, and ensuring seamless alignment between product design and assembly execution.

Key Responsibilities:

• Lead the definition of General Assembly process architecture, including line concepts, workstation design, tooling strategy, material flow, and line balancing.

• Drive the development and execution of Process FMEA (PFMEA) and Control Plans, ensuring assembly risks are identified, mitigated, and aligned with product maturity.

• Enable digital pre-assembly and digital manufacturing validation, including virtual builds, ergonomic simulations, and early issue detection.

• Develop and maintain early manufacturing readiness documentation, supporting phased execution, line design, manpower planning, and launch readiness reviews.

• Ensure assembly feasibility, serviceability, and quality requirements are incorporated into early product and system design decisions.

• Provide manufacturing inputs to support early facility layout, equipment selection, and capital investment decisions.

• Support pilot builds, pre-production activities, and production ramp-up execution.

• Support structured change management for product or process changes with cross-functional impact.

• Collaborate closely with Product Engineering, Quality, Supply Chain, and Construction teams.

Required Qualifications:

• Bachelor's degree in Engineering or related technical discipline.

• Strong experience in automotive General Assembly manufacturing engineering.

• Solid understanding of assembly processes, ergonomics, and manufacturing quality systems.

Preferred Qualifications:

• Experience with digital assembly, ergonomic simulation, or virtual build tools.

• Experience supporting greenfield manufacturing facilities or new plant launches.