Project Engineer

Bonnell Aluminum•South Carthage, TN

About The Position

Reporting to the Engineering Manager, the Project Engineer is responsible for supporting new product development, design work, and capital projects across mechanical and/or controls/electrical disciplines. This role requires working collaboratively in cross-functional teams to scope, write, justify, and manage CAPEX projects, as well as supporting new products requiring capital investment. The Project Engineer will support implementation of new equipment to include PFMEAs, risk analysis, work instructions, and control plans as required. This role is vital in supporting and expanding the plant’s continuous improvement culture.

Requirements

Bachelor’s Degree in an engineering discipline (Mechanical, Electrical, Manufacturing, Industrial, or related) or a minimum of 4 years of experience in a similar role.
Effective verbal and written communication skills.
Proficient in MS Office (Excel, PowerPoint, Teams, and Word).
ERP experience – preferably with J.D. Edwards or Oracle.

Nice To Haves

Previous project management and CAPEX experience preferred.
Lean Manufacturing and/or Lean Six Sigma exposure – Green Belt preferred.
3D Modeling Software /AutoCAD experience preferred.

Responsibilities

Lead projects from concept through design, procurement, installation, commissioning, and handover.
Define project scope, milestones, deliverables, budgets, and acceptance criteria; maintain detailed project schedules and risk registers.
Coordinate cross-functional teams (Operations, Maintenance, Quality, Supply Chain, EHS) to ensure alignment on goals and execution.
Effective communication of project schedule changes / progress to all stakeholders in a timely manner.
Conduct formal design reviews, change control, and stage-gate approvals.
Track project progress using KPIs and provide regular status reports to Engineering Manager and leadership.
Manage vendor relationships: RFQs, technical evaluations, bid comparisons, design reviews, and contract coordination.
Lead vendor quoting and selection activities for assigned projects.
Identify project risks and develop mitigation strategies to avoid delays or cost overruns.
Maintain budgetary, scheduling, and project plans in appropriate systems.
Develop engineering designs, layouts, equipment specifications, and system calculations for manufacturing equipment and processes.
Create and review 2D/3D CAD models, engineering drawings, and BOMs as applicable.
Provide solutions to technical problems using sound engineering practices.
Develop manufacturing processes for new products for assigned projects.
Create and administer appropriate testing protocols to monitor project performance.
Validate equipment performance through testing, trials, and commissioning activities.
Perform root-cause analysis and recommend design or process changes to improve equipment performance.
Support implementation of new equipment to include PFMEAs, risk analysis, work instructions, and control plans.
Calculate, track, and report cost savings to support site cost savings goals.
Support Engineering Change Requests (ECR) as assigned.
Participate in Lean/Six Sigma events and apply engineering solutions to reduce scrap, setup time, and variability.
Analyze production and downtime data to identify bottlenecks and improvement opportunities.
Supports business development team during new business quoting process.
Model safety and environmental behaviors that always align with company values, policies, and standards throughout the project life cycle.
Ensure compliance with all internal and external safety and quality standards and specifications (OSHA, ASME, ANSI, NFPA).
Develop and maintain engineering documentation, SOPs, and equipment manuals.
Conduct design reviews and safety assessments (FMEA, HAZOP, ergonomic evaluations) for new equipment and modifications.
Work with Maintenance to improve equipment reliability and optimize PM/RCM strategies.
Support Operations with troubleshooting of issues impacting safety, quality, or productivity.
Train operators and maintenance teams on new equipment operation, modifications, and installations.
Schedule and monitor resources to ensure project milestones are met.
Other tasks and projects as assigned to support the success of the plant.
Establish project objectives (scope), procedures, data collection methods, and performance standards within boundaries of corporate policy.
Prepare cost estimates, capital requests, and ROI analyses for engineering projects.
Gather and validate data to build clear problem statements that translate operational issues into measurable business impacts.
Collaborate with Operations, Maintenance, Finance, and EHS to review potential solutions and assess feasibility, risk, ROI, and alignment with long-term strategic goals.
Support stage-gate reviews and provide technical analysis and data required for approval.
After installation, perform post-implementation verification to ensure CapEx projects deliver targeted improvements.