Project Engineer

Casting Engineering Department is seeking a passionate, highly motivated Manufacturing Engineer who thrives in a hands-on, fast-paced manufacturing environment.

This role plays a critical part in delivering world-class casting equipment, tooling, and processes at the lowest possible cost while meeting safety, quality, and production objectives. You will support the TMNA Powertrain Casting Engineering organization and work closely with the Bodine Aluminum manufacturing site to bring major powertrain and BEV programs from concept to SOP.

• Lead large-scale capital projects for:

  • Existing Vehicle Powertrain Programs
    (Aluminum cylinder blocks, hybrid transmission cases, housings)

  • BEV Development Programs
    (STEP 3 e-Axle cases, housings, suspension members – SOP ~2027)

• Manage full project lifecycle (12–24 months), including:

  • Capital budget development

  • Equipment and die specification

  • Supplier management and procurement

  • Equipment installation and casting trials

  • Quality confirmation leading to SOP

• Manage project budgets typically ranging from $5M to $45M

• Study TMC-based processes and develop North America–specific Operation Drawings

• Support additional process initiatives such as:

  • Shikumi development

  • Hoshin (goal deployment) objectives

• Build and manage daily project “punchlists”

• Apply Toyota Business Practice (TBP) methodology to drive root cause analysis and countermeasures

• Lead defect investigation and product quality improvement activities

• Lead cross-functional project teams during pre-production phases

• Schedule and lead meetings, coordinate contractors, and manage equipment installation activities

• Review technical materials, align stakeholders, and drive consensus to meet project milestones

• Bachelor’s degree (or higher) in Engineering or equivalent experience
  (Mechanical, Metallurgical, Electrical, or related field)

• 3+ years of production preparation and/or manufacturing experience

• 1+ year of major model change experience (equipment, tooling, fixtures, transfers) with impact on quality and manufacturability

• 1+ year of experience as a project leader managing working groups and project milestones

• 3+ years of casting or metals manufacturing engineering experience

• 1+ year of High Pressure Die Casting (HPDC) experience

• 1+ year of hands-on NC machining experience

• 1+ year working knowledge of:

  • Fanuc robots (integration & troubleshooting)

  • Toyopuc PLCs (integration & troubleshooting)

• Experience with 2D/3D CAD systems for equipment layout and part/die modeling
  (AutoCAD, Creo, or similar)

• PLC programming and troubleshooting experience

• Proven experience preparing capital justifications and presenting for approval

• Successful completion of JKK and TBP

• Experience leading TEMA PE projects exceeding $5M

• Participation in TMNA project cycles from Planning through SOP