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Key Responsibilities and Required Skills for Manufacturing Project Engineer

💰 $80,000 - $120,000

EngineeringManufacturingProject ManagementContinuous Improvement

🎯 Role Definition

The Manufacturing Project Engineer leads cross-functional engineering projects that deliver new products, manufacturing process improvements, equipment installations, and CAPEX initiatives. This role coordinates design for manufacturability (DFM), suppliers, quality, operations and automation teams to ensure projects are delivered on schedule, on budget, and meet safety, cost, yield and quality targets. Ideal candidates are experienced in NPI (new product introduction), continuous improvement (Lean/Six Sigma), project management (PMP or equivalent), and hands-on problem solving in a high-mix / high-volume manufacturing environment.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Manufacturing Engineer
  • Process Engineer
  • Mechanical/Electrical Engineer (early-career)

Advancement To:

  • Senior Project Engineer / Program Engineer
  • Engineering Manager / Plant Engineering Manager
  • Program Manager / Operations Manager

Lateral Moves:

  • Continuous Improvement / Lean Engineer
  • Quality Engineer (APQP/PPAP lead)
  • Supplier Development Engineer

Core Responsibilities

Primary Functions

  1. Lead cross-functional manufacturing projects from concept through production launch, including scoping, budgeting, scheduling, resource allocation, risk management and post-launch stabilization to ensure on-time, on-budget delivery.
  2. Manage NPI (new product introduction) activities: coordinate design for manufacturability (DFM), prototype builds, pilot runs, and handover to production while documenting lessons learned and launch metrics.
  3. Develop and own detailed project plans (Gantt, critical path), define milestones, track progress, report status to stakeholders and escalate issues with mitigation strategies to senior management.
  4. Drive process development and standardization for assembly, test and material flow to reduce cycle time, scrap, rework and manufacturing cost while improving throughput and first-pass yield.
  5. Specify, source and manage capital equipment purchases and installations (CAPEX) including vendor selection, technical evaluation, FAT/SAT, installation, commissioning and qualification.
  6. Perform root cause analysis (8D, RCA) for recurring production issues; develop and implement corrective and preventive actions (CAPA) and verify effectiveness through data and control plans.
  7. Lead cross-functional DFMEA/PFMEA sessions and implement control plans to reduce process and product failure modes and support APQP deliverables.
  8. Coordinate with suppliers on component design, process controls and supplier quality improvement initiatives; drive supplier development and manage supplier PPAP submissions.
  9. Create and maintain manufacturing documentation: work instructions, SOPs, control plans, process flow diagrams, process capability studies (Cp, Cpk) and training materials for production teams.
  10. Integrate automation and PLC-based solutions with controls and robotics vendors to increase production efficiency and reduce operator variability.
  11. Conduct time and motion studies, layout optimization, and line balancing to improve ergonomics, safety and material flow using Lean tools (5S, Kaizen, Kanban).
  12. Partner with Quality Engineering to ensure product and process compliance with regulatory, customer and internal standards; support audits and customer site visits.
  13. Manage project budgets and cost-to-complete forecasts; identify cost-savings opportunities and perform ROI analysis for process improvements and equipment investments.
  14. Use CAD (SolidWorks, Creo, AutoCAD) and engineering drawings with GD&T to validate tooling, fixtures and assembly jigs while coordinating design changes with product engineering.
  15. Implement data-driven performance dashboards and KPIs (yield, throughput, downtime, OEE) to monitor project outcomes and continuous improvement initiatives.
  16. Define training plans and deliver hands-on training for operators, supervisors and maintenance staff to ensure process reproducibility and safety compliance.
  17. Oversee installation, validation and handover of test fixtures, inspection equipment, and metrology solutions to secure reliable in-process and final inspection.
  18. Ensure environmental, health & safety (EHS) requirements are met during project execution, including risk assessments, lockout/tagout procedures and machine guarding.
  19. Support product cost reduction and value engineering by identifying material, component and process alternatives while maintaining quality and regulatory requirements.
  20. Coordinate cross-site or global launches, harmonize processes across facilities, and manage travel to supplier and plant locations as required.
  21. Maintain strong documentation and change control (ECO/ECR) processes for manufacturing process and product changes to support traceability and continuous improvement.
  22. Mentor and coach junior engineers and technicians, fostering a culture of continuous improvement and technical excellence on the shop floor.

Secondary Functions

  • Support ad-hoc production troubleshooting and rapid response teams during line outages or quality escapes.
  • Collaborate with procurement and supply chain to manage lead times, inventory buffers and risk mitigation for critical components.
  • Contribute to manufacturing strategy reviews and provide technical input for long-term capacity planning and facility upgrades.
  • Assist in developing RFPs and vendor evaluations for equipment and automation suppliers.
  • Participate in cross-functional kaizen events, cost-reduction workshops, and periodic process capability reviews.

Required Skills & Competencies

Hard Skills (Technical)

  • New Product Introduction (NPI) lifecycle management and production launch expertise.
  • Project management: project plans, scheduling, risk mitigation, budget tracking (experience with MS Project, Smartsheet, or equivalent).
  • Lean manufacturing and continuous improvement methodologies: Kaizen, 5S, Value Stream Mapping.
  • Six Sigma tools and statistical analysis (DMAIC, SPC, Minitab) and experience driving process capability improvements (Cp, Cpk).
  • Design for Manufacturability (DFM) and Design for Assembly (DFA) principles.
  • Failure mode analysis (DFMEA / PFMEA) and corrective action implementation (8D, CAPA).
  • Geometric Dimensioning & Tolerancing (GD&T), engineering drawings and CAD (SolidWorks, Creo, AutoCAD).
  • Equipment specification, procurement and commissioning for automated assembly and test systems; familiarity with PLC controls and robotics integration.
  • Quality systems and manufacturing standards: APQP, PPAP, ISO 9001, IATF 16949 (where applicable).
  • Supplier development and quality management, including supplier PPAP and performance metrics.
  • Data analysis and KPI reporting: OEE, throughput, yield, scrap rates; experience building dashboards (Excel, Tableau, Power BI).
  • Cost modeling, BOM cost-down strategies and CAPEX ROI justification.
  • Familiarity with ERP/MRP systems (SAP, Oracle, Epicor) and ECO/Change control workflows.
  • Test engineering and metrology: gauge R&R, fixture design, test plans and functional verification.
  • Hands-on mechanical aptitude for fixture, tooling and small-batch fabrication troubleshooting.

Soft Skills

  • Strong cross-functional leadership and stakeholder management across engineering, operations, quality and supply chain.
  • Clear written and verbal communication: able to prepare executive-level status reports and detailed technical documentation.
  • Problem-solving and analytical mindset with urgency for root-cause resolution and results orientation.
  • Organizational skills and attention to detail to manage multiple concurrent projects and deliverables.
  • Adaptability and resilience in a fast-paced manufacturing environment with shifting priorities.
  • Coaching and mentorship skills to develop junior engineering talent and shop-floor champions.
  • Negotiation and vendor management capabilities to secure favorable terms and technical outcomes.
  • Customer-focused approach to align manufacturing decisions with product performance and delivery expectations.
  • Time management and task prioritization for on-time execution and milestone achievement.
  • Collaborative teamwork and facilitation skills to run effective cross-functional meetings and design reviews.

Education & Experience

Educational Background

Minimum Education:

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

Preferred Education:

  • Master’s degree in Engineering, MBA, or advanced technical certification (PMP, Six Sigma Black Belt, Lean Certification).

Relevant Fields of Study:

  • Mechanical Engineering
  • Industrial / Manufacturing Engineering
  • Electrical Engineering
  • Mechatronics / Automation Engineering
  • Materials Science / Engineering

Experience Requirements

Typical Experience Range: 3–8+ years of progressive experience in manufacturing engineering, project management or process engineering roles.

Preferred:

  • 5+ years leading manufacturing projects, NPI launches, CAPEX installations or cross-functional process improvements.
  • Demonstrated experience with automation/robotics integration, supplier development, APQP/PPAP, and statistical process control.
  • Experience in your industry vertical (electronics, automotive, medical devices, aerospace, consumer products) preferred when relevant.
  • Certifications such as PMP, Six Sigma Green/Black Belt, Lean Practitioner or relevant vendor equipment certifications are a plus.
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