Senior Manufacturing Engineer - Stamping

Job Title: Senior Manufacturing Engineer - Stamping 

Location: California - USA

Level: Senior

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:

Responsible for defining, developing, and validating stamping manufacturing processes to support a new vehicle program and greenfield factory launch. This role ensures robust process design, early manufacturing readiness, and alignment with product, manufacturing, and construction activities.

Key Responsibilities:

• Define stamping process architecture, including press requirements, die concepts, automation, and material flow.
• Conduct early process feasibility evaluations using CAD/CAE tools to ensure parts can be manufactured without defects like splitting or wrinkling.
• Develop and maintain Process FMEA (PFMEA) and Control Plans for stamping operations.
• Prepare and maintain early manufacturing readiness documentation to support tooling, facility layout, and investment decisions.
• Collaborate with Product Engineering to ensure manufacturability, dimensional control, and quality robustness.
• Lead "buy-off" events where new dies are tested for part accuracy and construction quality before they are shipped to the plant.
• Resolve complex formability issues on-site during tryout events using die compensation strategies.
• Manage start-up activities and die pre-production schedules to align with the overall vehicle launch timeline.
• Collaborate with Body-in-White (BIW), Quality, and Design teams to ensure stamped panels integrate seamlessly into the final vehicle assembly.
• Oversee formal PPAP (Production Part Approval Process) and PSW (Part Submission Warrant) documentation to verify that production processes are stable.
• Support structured change management for cross-functional products or process changes.

Required Qualifications:

• Bachelor’s degree in Engineering or related field.
• Experience in automotive stamping in high-volume new model launch.
• Strong knowledge of PFMEA, Control Plans, and manufacturing quality systems.
• Experience supporting new product introduction and manufacturing readiness.
• Proficiency in simulation software like Autoform, Dyna, or PAM-STAMP, alongside CAD tools such as CATIA or UG NX.
• Deep understanding of GD&T (Geometric Dimensioning and Tolerancing), press automation sequencing, and material flow.

Preferred Qualifications:

• Experience with greenfield factory launches.
• Ability to track metrics using scorecards and trackers to meet "non-event launch" goals.
• Experience working within OEM-style program governance models.