General Assembly Tooling Engineer

Job Title: General Assembly Tooling Engineer

Location: Warsaw, Indiana

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:

The GA Tooling Engineer serves as the technical authority for the design, procurement, and maintenance of all General Assembly assets. This role is responsible for ensuring that all tooling—from initial drawings to final production floor deployment—is high-performing, cost-effective, and capable of meeting strict product tolerances. You will bridge the gap between design concepts and physical production by managing global vendors and optimizing tool performance throughout the product lifecycle.

Key Responsibilities:

• Tool Design & Development: Generate comprehensive tooling drawings and technical specs aligned with product tolerances. Facilitate Design for Tooling reviews with cross-functional teams to ensure manufacturability and quality compliance.


• Tool Procurement & Vendor Management: Manage the end-to-end sourcing process, including vendor selection, price negotiation, and performance auditing based on cost, quality, and lead time. Monitor fabrication progress to ensure deliveries align with established Program Timelines.


• Tool Validation & Approval: Execute formal tool trials and dimensional inspections to verify performance. Provide final technical approval and documentation for quality release into the production environment.


• Maintenance & Troubleshooting: Establish rigorous maintenance schedules and critical spare parts inventories. Provide rapid-response troubleshooting and root cause analysis for tooling-related issues to minimize downtime.


• Cost & Efficiency Optimization: Identify and implement tooling modifications aimed at cycle time reduction and scrap minimization. Track Total Cost of Ownership and provide data-driven recommendations for process improvements.


• New Program Launch Support: Serve as the technical lead for tooling readiness during pilot builds and ramp-up. Coordinate all tooling revisions resulting from Engineering Change Orders to ensure seamless transitions.

Required Qualifications:

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, or a related technical discipline.


• 5+ years of experience in tooling design and procurement within a high-volume manufacturing environment.


• Mastery of CAD software and a deep understanding of GD&T (Geometric Dimensioning and Tolerancing).


• Proven ability to manage external vendors and meet strict program milestones and budget targets.


• Skills in managing large-scale capital equipment projects from inception to launch.


• Ability to provide immediate, on-floor issue resolution during critical build phases.


• Interfacing effectively with different stakeholders, including design engineers, production teams, and outside vendors.


• Exceptional verbal and written skills for authoring specifications and presenting technical status updates.


• Ability to perform under pressure during high-stakes "launch phases" and adjust to changing build requirements.

Preferred Qualifications:

• Experience with simulation software to predict tool performance.


• Lean Six Sigma certification or formal training in Root Cause Analysis (RCA) methodologies.


• Experience managing international tooling vendors and logistics.