Manufacturing Body Shop Engineer

Job Title: Senior Manufacturing Engineer / Manufacturing Engineering Manager - Body Shop

Location: California, Preferred or United States with travel

Level: Senior

Client Facing: Yes

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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:

The Body Construction Manufacturing Engineer is responsible for the development, implementation, and optimization of vehicle body structures and assembly processes (Body-In-White). This role requires a strong focus on structural integrity, manufacturing feasibility, quality assurance, and the coordination of automation equipment. He manages projects from initial concept through to full production launch, ensuring all processes meet safety, quality, and cost targets.

Key Responsibilities:

• Process & Feasibility Analysis: Conduct Process and Spotweld pattern feasibility studies to ensure designs can be efficiently manufactured. Develop process sheets, FMEAs (Failure Modes and Effects Analysis), and Control Plans to mitigate risk and maintain quality standards.

• Fixture & Equipment Procurement: Manage the full lifecycle of fixtures for subassembly lines and full framing cell. This includes layout definition and Capex estimation, developing Request for Quotations (RFQ), recaps, design reviews, construction, buyoff, and final installation, including integration with conveyors and dimensional control systems.

• Launch Support: Support launch phases, which involve issue resolution on the shop floor.

• Coordination Build: Lead the Coordination Build Events, from fixture specification and procurement through subassembly builds and complete vehicle build raising dimensional issues and discussing with Stamping and Suppliers their resolution.

• Dimensional Control & Quality: Develop and implement dimensional control and measurement plans, managing CMM (Coordinate Measuring Machine) specifications and installations to achieve precise dimensional coordination.

• Welding & Quality Verification: Act as a Weld Specialist, managing weld gun set-ups, and conducting tear-down tests and analysis to systematically verify product construction, identify hidden issues, and ensure structural performance and quality improvements.

• Automation & Process Improvement: Oversee the integration of automation equipment, perform cycle time and downtime analyses, and drive continuous process improvement initiatives to enhance efficiency and productivity.

Required Qualifications:

• Education: Bachelor’s degree in Mechanical, Electrical, Industrial, or Manufacturing Engineering.

• Experience: 10–15+ years of professional experience in automotive Body-in-White (BIW) manufacturing.

• Proven experience evaluating manufacturing feasibility in early stages of the development of new products.

• Experience developing RFQs for framing cells and fixtures, including vendor buyoffs and integration with robotics and conveyors.

• Proficiency in CAD software for process feasibility studies and fixture design reviews.

• Ability to conduct cycle time and downtime analysis to drive shop-floor efficiency.

• Leading "Coordination Build Events" by aligning Stamping teams, external suppliers, and internal design engineers.

• Resolving complex dimensional or assembly issues quickly during high-pressure launch phases.

• Effectively discussing technical deviations and corrective actions with suppliers and stakeholders.

• Meticulousness in verifying weld patterns and structural "hidden issues" that affect vehicle safety.

Preferred Qualifications:

• Deep expertise in Spot Welding, MIG/TIG welding, and destructive testing (tear-down analysis) to verify structural integrity.

• Proficiency in Geometric Dimensioning and Tolerancing (GD&T) and using CMM (Coordinate Measuring Machines) or laser scanning for precision validation.

• Development of PFMEA (Process Failure Mode and Effects Analysis), Control Plans, and Process Sheets.