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Tolerance Analysis Jobs in Michigan (NOW HIRING)

Experience with tolerance analysis, mold flow, AAR approval. * Advanced skills in Microsoft Excel, Word, and PowerPoint. Working knowledge of Smartsheets, JMP, Minitab, JIRA and Tableau is a plus.

Experience with tolerance analysis, mold flow, AAR approval. * Advanced skills in Microsoft Excel, Word, and PowerPoint. Working knowledge of Smartsheets, JMP, Minitab, JIRA and Tableau is a plus.

Experience with tolerance analysis, mold flow, AAR approval. * Advanced skills in Microsoft Excel, Word, and PowerPoint. Working knowledge of Smartsheets, JMP, Minitab, JIRA and Tableau is a plus.

Include design reviews, DFMEA / PFMEA documents, PPAP packages, tolerance analyses, benchmarking decks, test reports, and email threads. * Design multi-step tasks grounded in real workflows. Require ...

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Tolerance Analysis information

What are the key skills and qualifications needed to thrive in tolerance analysis, and why are they important?

To thrive in a Tolerance Analysis role, a strong background in mechanical engineering, manufacturing processes, and geometric dimensioning and tolerancing (GD&T) is essential, often supported by an engineering degree. Proficiency with CAD software, statistical analysis tools, and tolerance analysis applications like CETOL or Sigmetrix is commonly required. Attention to detail, problem-solving abilities, and clear communication are key soft skills that enhance effectiveness in this position. These skills ensure accurate analysis of part tolerances, reduce manufacturing errors, and foster successful collaboration with design and production teams.

What are the typical responsibilities of someone working in tolerance analysis?

Professionals in Tolerance Analysis are responsible for evaluating and defining the allowable variations in dimensions and assembly of mechanical parts to ensure products meet both quality and functional requirements. Their daily tasks often include reviewing engineering drawings, performing tolerance stack-ups, collaborating with design engineers to improve manufacturability, and documenting their analyses. Tolerance analysts frequently work as part of a multidisciplinary team, providing crucial input during the design and manufacturing stages to identify and mitigate potential assembly issues. This role is vital in industries such as automotive, aerospace, and consumer products, where ensuring reliable part fits and minimizing production risks are top priorities.

What is tolerance analysis?

A Tolerance Analysis job involves evaluating and controlling the dimensional variation of mechanical parts and assemblies to ensure proper fit, function, and manufacturability. Engineers performing tolerance analysis use statistical methods, CAD software, and geometric dimensioning and tolerancing (GD&T) principles to assess the impact of variations in production. This role helps optimize designs for cost efficiency, quality, and reliability while minimizing defects and assembly issues.

What cities in Michigan are hiring for Tolerance Analysis jobs? Cities in Michigan with the most Tolerance Analysis job openings:
Infographic showing various Tolerance Analysis job openings in Michigan as of August 2026, with employment types broken down into 71% Full Time, and 29% Contract. Highlights an 91% In-person, and 9% Hybrid job distribution.

Staff Hardware Engineer - DFx (Manufacturing, Test & Tooling)

General Motors

Warren, MI

Full-time

Medical, Dental, Vision, Life, Retirement, PTO

Re-posted 25 days ago


General Motors rating

8.2

Company rating: 8.2 out of 10

General Motors

Based on 306 frontline employees who took The Breakroom Quiz

7.4

Company rating compared to similar companies: 7.4 out of 10

Automakers average

Based on 6,274 frontline employees who took The Breakroom Quiz


Job description

Job Description

The Role:

General Motors is leading the transformation of the automotive industry through electrification, central compute, and autonomous technologies. We are building a high-energy team of Senior DFx (Design for Manufacturing, Test, and Tooling) engineers to serve as the critical link between internal design teams and contract manufacturers for next-generation ECUs.

This team will establish and drive DFx processes for in-house GM designs, ensuring strong alignment between design and manufacturing. They will bring early insight into manufacturing, assembly, testing, and tooling-embedding best practices, lessons learned, and critical requirements into module development.

We are seeking a high-performing Staff DFx Engineer to represent the voice of manufacturing, testing, and tooling across GM's electronics development. This role focuses on circuit board design, population, test, and assembly, working closely with both internal design teams and external manufacturing partners.

You will lead DFx strategy and execution for electrical controllers supporting GM's Software Defined Vehicle (SDV) architecture, while building strong, cross-functional partnerships to ensure successful product delivery.

Responsibilities of the Design for Manufacturing, Design for Testing, Tooling Engineer include:

  • Work with cross functional teams for the selection of test point location, in-circuit board coverage, functional test requirements from design teams, and programming requirements from design/CM teams.
  • Expertise in process from bare board to fully populated, soldered, tested PCB
  • Expertise in Solder Paste/Stencil process and materials, SPI Solder process Inspection, Acceptance Criteria, SMD placement, line loading, AOI, Reflow profile, Intermetallic and PCB surface finish
  • Perform design calculations, GD&T and tolerance stacks required for tooling and test fixtures
  • Create 3D CAD, 2D CAD & lead CAD reviews with stakeholders.
  • Develop analysis and test plans for new designs, perform proof of concept tests and analysis.
  • Lead prototyping and testing, analyze test data, and make necessary adjustments to manufacturing process/materials, in-plant testing and tooling designs.
  • Work with electrical engineers and PCBA designers to integrate components into test fixtures for in-circuit, functional, and in-process SW programming.
  • Build partnerships with functional peers internally within GM and externally at CM suppliers to align on ECU design per development cycles.
  • Develop virtualization technologies that help accelerate and de-risk product development.
  • Communicate Contract Manufacturing progress and risks to stakeholders and customers.
  • Drive Cross CM strategies for commonality within GM's in-house designs.
  • Solid organizational skills and the ability to manage multiple projects simultaneously.

Your Skills & Abilities (Required Qualifications)

  • BS in Electrical or Mechanical Engineering or equivalent engineering degree
  • 7+ years in-plant electronic control module manufacturing experience leading a cross functional team of Design/Manufacturing engineers for best in class DFM and DFT designs
  • Collaborative, team centered experience which leads to on-time delivery of quality products
  • Exceptional collaboration and teamwork skills; demonstrated ability for working across functional and organizational boundaries.
  • Proficiency in 3D CAD modeling, 2D drawings, schematic designs, test SW development, tolerance analysis, design for manufacturability, and assembly.
  • Strong analytical skills and engineering fundamentals in manufacturing, testing, tooling of automotive electronic modules.
  • Hands-on experience engaging with electronics manufacturers.

What Will Give You A Competitive Edge (Preferred Skills)

  • Master's degree/PhD in Electrical or Mechanical Engineering
  • Mechanical design of PCBAs, computers, or automotive electronics
  • Experience establishing a DFx organization within an automotive OEM.
  • Industry leading expertise with aspects of manufacturing including: Designed SMT placement equipment, solder reflow equipment, Developed AOI, SPI, Assembly line transfer equipment.

Compensation: The compensation information is a good faith estimate only. It is based on what a successful applicant might be paid in accordance with applicable state laws. The actual base salary a successful candidate will be offered within this range will vary based on factors relevant to the position, as well as geography of the selected candidate.
The salary range for this role is (159,400 to 245,000). The actual base salary a successful candidate will be offered within this range will vary based on factors relevant to the position.
Bonus Potential: An incentive pay program offers payouts based on company performance, job level, and individual performance.
Benefits:
Benefits: GM offers a variety of health and wellbeing benefit programs. Benefit options include medical, dental, vision, Health Savings Account, Flexible Spending Accounts, retirement savings plan, sickness and accident benefits, life insurance, paid vacation & holidays, tuition assistance programs, employee assistance program, GM vehicle discounts and more.

#LI-JK3

GM does not provide immigration-related sponsorship for this role. Do not apply for this role if you will need GM immigration sponsorship now or in the future. This includes direct company sponsorship, entry of GM as the immigration employer of record on a government form, and any work authorization requiring a written submission or other immigration support from the company (e.g., H1-B, OPT, STEM OPT, CPT, TN, J-1, etc). This role is categorized as hybrid. This means the selected candidate is expected to report to a specific location at least 3 times a week {or other frequency dictated by their manager}. The selected candidate will be required to travel <25% for this role. This job is not eligible for relocation benefits. Any relocation costs would be the responsibility of the selected candidate.

About GM

Our vision is a world with Zero Crashes, Zero Emissions and Zero Congestion and we embrace the responsibility to lead the change that will make our world better, safer and more equitable for all.

Why Join Us

We believe we all must make a choice every day - individually and collectively - to drive meaningful change through our words, our deeds and our culture. Every day, we want every employee to feel they belong to one General Motors team.

Benefits Overview

From day one, we're looking out for your well-being-at work and at home-so you can focus on realizing your ambitions. Learn how GM supports a rewarding career that rewards you personally by visiting Total Rewards resources.

Non-Discrimination and Equal Employment Opportunities (U.S.)

General Motors is committed to being a workplace that is not only free of unlawful discrimination, but one that genuinely fosters inclusion and belonging. We strongly believe that providing an inclusive workplace creates an environment in which our employees can thrive and develop better products for our customers.

All employment decisions are made on a non-discriminatory basis without regard to sex, race, color, national origin, citizenship status, religion, age, disability, pregnancy or maternity status, sexual orientation, gender identity, status as a veteran or protected veteran, or any other similarly protected status in accordance with federal, state and local laws.

We encourage interested candidates to review the key responsibilities and qualifications for each role and apply for any positions that match their skills and capabilities. Applicants in the recruitment process may be required, where applicable, to successfully complete a role-related assessment(s) and/or a pre-employment screening prior to beginning employment. To learn more, visit How we Hire.

Accommodations

General Motors offers opportunities to all job seekers including individuals with disabilities. If you need a reasonable accommodation to assist with your job search or application for employment, email us or call us at 1-800-865-7580. In your email, please include a description of the specific accommodation you are requesting as well as the job title and requisition number of the position for which you are applying.


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About General Motors

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General Motors is a company with global scale and capabilities, headquartered in Detroit, Michigan, with employees around the world. The company employs over 165,000 people, serves six continents, operates across 22 time zones, and has a diverse workforce speaking 75 languages1. GM’s vision is to drive the world forward by pioneering innovations that move and connect people to what matters. The company is working towards an all-electric future with its new Ultium Platform and is pushing transportation options beyond our wildest imaginations with autonomous vehicles. GM is also committed to becoming the most inclusive company in the world.

Industry

Transportation equipment manufacturing

Company size

10,000+ Employees

Headquarters location

Detroit, MI, US

Year founded

1908