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Jobs · Quality Assurance · Michigan

Development & Validation Engineer

General Motors · Warren, MI · 1 wk ago
On-siteQuality AssuranceFull-time

This Development & Validation Engineer serves as the technical lead for TRP-related physical testing and Design Failure Mode and Effects Analysis (DFMEA) detection within the RESS Development & Validation organization.

About the role

The role owns planning and execution of TRP lab activities and ensures that results are tightly linked to the DFMEA, enabling risk-based prioritization for propulsion programs. Roughly 70% of the role is hands-on technical execution in the lab and with hardware, and 30% is strategy, leadership, and cross-functional coordination across Global Virtual Engineering (GVE), GPDV, safety, and program teams.

Responsibilities

  • TRP Physical Test Planning & Execution (70%)
    • Develop and maintain detailed TRP test plans and procedures covering cell, module, and pack levels, aligned to program timing and safety requirements.
    • Lead day-to-day execution of TRP tests in the lab: hardware readiness, test setup, instrumentation, and on-the-floor issue resolution.
    • Ensure test configurations accurately represent design intent, including hardware deviations and associated rationale.
    • Drive high-quality data collection, repeatability, and documentation; author clear test reports and technical summaries.
    • Partner with safety, design, and systems teams to interpret TRP results, identify failure mechanisms, and define design/test countermeasures.
  • DFMEA Detection & Risk-Based Prioritization (20%)
    • Act as the TRP physical “detection owner” for relevant DFMEA line items: ensure every significant TRP failure mode has a defined and appropriate physical detection method.
    • Use DFMEA scoring (S/O/D and resulting risk rankings) as a prioritization tool—to sort and cluster work—rather than as an “absolute grade” to optimize.
    • Regularly review DFMEA rankings with GVE/GPDV partners to decide which TRP tests to run next, which analyses are most valuable, and where method improvements are needed.
  • Leadership, Collaboration & Ways of Working (10%)
    • Serve as the primary TRP physical voice in the Thermal/TRP workgroup: present status, gaps, and recommendations, and ensure actions are captured and owned.
    • Coordinate closely with virtual (GVE) teams to align TRP tests with modeling assumptions, correlations, and capability gaps.
    • Contribute to continuous improvement of TRP methods, fixtures, instrumentation, and standard work.

Requirements

  • Bachelor’s degree in Mechanical Engineering, Electrical Engineering, Chemical Engineering, Materials Science, or related field.
  • Minimum 2+ years relevant experience.
  • Demonstrated hands-on experience planning and executing complex lab tests (preferably thermal or abuse testing) with strong attention to safety.
  • Working knowledge of DFMEA or similar risk-assessment tools, with experience linking test plans to failure modes.
  • Proven ability to interpret complex test data, identify root causes, and communicate technical conclusions clearly in writing and verbally.

Preferred Qualifications

  • Experience with TRP, battery safety, or high-energy systems testing (e.g., thermal runaway, abuse, containment, venting).
  • Prior ownership of DFMEAs or similar tools for safety-critical systems, including experience with S/O/D scoring and risk-based prioritization.
  • Familiarity with GVDP/GPDP and propulsion program execution (scorecards, PRTS, gate deliverables).
  • Experience working cross-functionally with GVE, safety, program management, and suppliers.
  • Demonstrated capability to influence without authority and drive alignment across multiple stakeholders.

Behavioral Expectations

  • Operates with a strong safety and quality mindset in all lab activities.
  • Uses data and DFMEA rankings to focus effort on the highest-value work, avoiding “test for test’s sake.”
  • Communicates proactively, escalates risk early, and brings structured options and recommendations.
  • Comfortable switching between hands-on lab execution and higher-level risk/strategy discussions with leadership.

GM does not provide immigration-related sponsorship for this role. This role is categorized as onsite, requiring the selected candidate to report to a specific location full-time. Travel is expected to be less than 25%. Relocation benefits are not provided for this position.

Benefits

From day one, GM supports your well-being at work and at home. Learn more about the comprehensive benefits offered by visiting Total Rewards resources.

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