Project Engineer

Project Engineer – Manufacturing (APQP / Launch) Gastonia, North Carolina (On-site) About the Company IFAB Corp. is a growing custom metal fabrication manufacturer serving transportation and industrial markets. Our capabilities include stamping, forming, robotic and manual welding, CNC machining, assembly, and advanced coating processes (paint and e-coat).

We operate in a fast-paced, Lean-driven environment where engineering, production, and quality collaborate closely on the shop floor to deliver high-performance solutions.

About the Role

This role is ideal for a hands-on Project Engineer who thrives in a manufacturing environment and takes full ownership of product launches from concept through production. You will play a critical role in ensuring successful program execution across safety, quality, delivery, and cost while acting as the central point of coordination between customers, suppliers, and internal teams.

Key Responsibilities

Lead end-to-end APQP activities for new product launches involving stamped, formed, welded, machined, and coated components. Own program timelines, milestones, risk tracking, and launch readiness, ensuring all deliverables meet customer and internal requirements. Develop and maintain core APQP documentation including PFMEA, Process Flow Diagrams, and Control Plans in collaboration with Manufacturing, Quality, and Operations teams.

Manage full PPAP submission process (Levels 1–5 as required), ensuring accuracy, completeness, and on-time customer approvals. Serve as the primary customer interface for assigned programs, providing regular updates, managing expectations, and resolving technical or timing issues. Coordinate with tooling vendors, raw material suppliers, and outside processing partners to ensure readiness aligned with production schedules.

Drive manufacturability reviews (DFM/DFA) and support process design, including fixture development, tooling validation, and capacity planning. Lead cross-functional launch meetings, track open issues, and ensure timely closure of risks related to quality, delivery, and cost. Support production ramp-up by troubleshooting process issues, reducing variation, and ensuring stable, repeatable manufacturing conditions.

Monitor early production performance metrics (scrap, rework, first-pass yield, customer complaints) and implement corrective actions as needed. Ensure compliance with ISO 9001 / IATF 16949 standards and customer-specific requirements throughout the launch lifecycle. Maintain accurate ERP/MRP system data including BOMs, routings, and project cost tracking.

Actively participate in continuous improvement initiatives, applying Lean and Six Sigma principles to optimize processes. Spend significant time on the production floor collaborating with operators, supervisors, and quality teams to ensure successful execution.

Qualifications

Bachelor’s degree in Industrial, Mechanical, or Manufacturing Engineering, Business, or equivalent hands-on manufacturing experience. 3+ years of experience in automotive, aerospace, or industrial manufacturing environments. Working knowledge of APQP, PPAP, and quality systems within ISO 9001 and/or IATF 16949 frameworks.

Ability to interpret technical drawings, GD&T, specifications, BOMs, and routings. Experience with ERP/MRP systems (e.g., Sage, SAP, or similar). Strong project management skills with the ability to manage multiple programs simultaneously in a fast-paced environment.

Required Skills

Proven ownership of product launches for OEM or Tier 1 customers and new customers Experience in metal fabrication processes such as stamping, welding, CNC machining, and coating systems. Strong problem-solving skills with a data-driven approach. Effective communication skills across shop floor, suppliers, and customers.

Bilingual (English/Spanish) preferred to support a diverse workforce and customer base.

Preferred Qualifications

Lean Manufacturing or Six Sigma certification. Project Management certification (PMP or equivalent). Experience with tooling development and capital equipment launches. What Success Looks Like On-time, on-budget product launches with zero delayed PPAP submissions. Stable production processes with strong early quality performance (low scrap and rework).

High customer satisfaction with minimal launch-related disruptions. Well-documented, audit-ready APQP and production processes. Why Join IFAB Direct impact: See your work move from concept to production and into customer applications. Hands-on environment: Work closely with operations in a highly collaborative, shop-floor-driven culture.

Growth opportunities: Exposure to customers, leadership, and cross-functional teams with clear paths for advancement. Continuous improvement culture: Be part of a team that values practical problem-solving and operational excellence.