Project Engineer-Manufacturing & Automation

Aegis Worldwide; Lake Villa (IL); On-site; USD 80,000 - 90,000; Full time

Job summary

Aegis Worldwide is seeking a hands-on Project Engineer to drive equipment performance, expand automation, and increase efficiency in a high-volume aluminum manufacturing environment. You will own projects from problem identification through testing, implementation, and documenting results.

The ideal candidate has 2–5 years in engineering, strong mechanical aptitude, and the ability to lead upgrades, troubleshoot production issues, and collaborate with Maintenance, Production, OEMs, and

Qualifications

• 2–5 years of engineering experience in a high-volume manufacturing environment.
• Experience independently leading equipment upgrades, manufacturing efficiency initiatives, or cost savings projects through implementation.
• Strong mechanical aptitude and an understanding of how production machinery operates.
• Hands-on experience troubleshooting equipment and resolving production process issues.
• Ability to gather input from operators and maintenance technicians, identify root causes, test solutions, and implement improvements.
• Strong communication, documentation, and project coordination skills.
• Willingness to spend most of the workday on the production floor.

Responsibilities

• Lead equipment improvement, automation, and continuous improvement projects from concept through implementation.
• Identify opportunities to reduce manual labor, improve material flow, reduce scrap, and increase equipment reliability and productivity.
• Improve presses and thermoforming equipment through automated part handling, stacking, and other process enhancements.
• Evaluate and integrate sensors, vision systems, and automated quality inspection or sampling technologies.
• Troubleshoot underperforming equipment alongside Maintenance and Production, identify root causes, and test potential solutions.
• Develop and validate improvements through offline testing, prototyping, and production trials.
• Evaluate machine functions and coordinate equipment modifications, upgrades, or rebuilds to improve performance.
• Work with equipment OEMs, component suppliers, and outside integrators to evaluate and implement solutions.
• Use CAD and, when appropriate, 3D printing to develop basic fixtures, sensor mounts, and prototype components.
• Create or update work instructions and communicate process changes to affected teams.
• Document project objectives, testing results, cost savings, and operational improvements; present findings to plant leadership.

Skills

Engineering experience

Project leadership

Mechanical aptitude

Troubleshooting

Communication

On-floor work

Education

Bachelor’s degree in Engineering

Tools

SolidWorks

AutoCAD

3D printing

Job description

Project Engineer – Manufacturing & Automation

Compensation: $80,000–$90,000 base salary plus bonus opportunity

Industry: Aluminum Manufacturing

About the Opportunity

An established manufacturer is seeking a hands-on Project Engineer to improve equipment performance, expand automation, and increase efficiency in a high-volume production environment.

This position owns projects from identifying the problem and evaluating solutions through testing, implementation, and documenting results. Approximately 90% of the role involves production-floor equipment evaluation, troubleshooting, and improvement implementation. Basic mechanical design and prototyping account for approximately 5–10%.

The ideal candidate combines strong mechanical aptitude with the ability to work independently and collaborate with Production, Maintenance, equipment manufacturers, and outside suppliers.

Key Responsibilities

• Lead equipment improvement, automation, and continuous improvement projects from concept through implementation.
• Identify opportunities to reduce manual labor, improve material flow, reduce scrap, and increase equipment reliability and productivity.
• Improve presses and thermoforming equipment through automated part handling, stacking, and other process enhancements.
• Evaluate and integrate sensors, vision systems, and automated quality inspection or sampling technologies.
• Troubleshoot underperforming equipment alongside Maintenance and Production, identify root causes, and test potential solutions.
• Develop and validate improvements through offline testing, prototyping, and production trials.
• Evaluate machine functions and coordinate equipment modifications, upgrades, or rebuilds to improve performance.
• Work with equipment OEMs, component suppliers, and outside integrators to evaluate and implement solutions.
• Use CAD and, when appropriate, 3D printing to develop basic fixtures, sensor mounts, and prototype components.
• Create or update work instructions and communicate process changes to affected teams.
• Document project objectives, testing results, cost savings, and operational improvements; present findings to plant leadership.

Required Qualifications

• 2–5 years of engineering experience in a high-volume manufacturing environment, with a focus on project engineering, manufacturing engineering, process engineering, industrial engineering, capital projects, or continuous improvement.
• Experience independently leading equipment upgrades, manufacturing efficiency initiatives, or cost savings projects through implementation.
• Strong mechanical aptitude and an understanding of how production machinery operates.
• Hands-on experience troubleshooting equipment and resolving production process issues.
• Ability to gather input from operators and maintenance technicians, identify root causes, test solutions, and implement improvements.
• Strong communication, documentation, and project coordination skills.
• Willingness to spend most of the workday on the production floor.

Preferred Qualifications

• Bachelor’s degree in Engineering, preferably Mechanical, Manufacturing, or Industrial Engineering.
• Experience with high-speed presses, thermoforming equipment, or packaging operations.
• Experience with industrial automation, sensors, vision systems, automated material handling, or labor-reduction projects.
• Working knowledge of SolidWorks or AutoCAD for basic 2D and 3D mechanical design.
• Experience coordinating with equipment OEMs, suppliers, and outside integrators.
• Familiarity with 3D printing, fixture design, and prototype testing.

Scheduling Requirement

Candidates must be comfortable with an annual PTO blackout period from September 1 through December 1.