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.
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