About the role
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.