Senior Project Engineer

Senior Project Engineer Summary

The Senior Project Engineer serves as the plant's senior technical leader for automation, controls, machine safety, manufacturing technology, and capital project execution. This position is responsible for developing and executing automation strategies, leading manufacturing modernization initiatives, and managing projects ranging from continuous improvement efforts to multi-year capital programs. This role will also establish machine safety standards and best practices for the facility, including their incorporation into 6S audits and standards.

The Senior Project Engineer acts as the primary technical bridge between Process Engineering, EHS, Operations, Maintenance, Safety, IT, and MES Engineering to improve safe manufacturing performance through automation, digital transformation, process optimization, and equipment modernization. This role is responsible for developing long-term technology roadmaps, improving manufacturing data visibility, reducing operational risk, and driving sustainable improvements in safety, quality, productivity, reliability, and cost performance. The position complements the Senior MES Engineer by defining manufacturing technology strategy and controls architecture while leading implementation of automation, safety, and modernization projects.

Primary Responsibilities

Manufacturing Technology Leadership

• Develop and maintain the site's automation, controls, and digital manufacturing strategy.
• Establish plant standards for PLCs, HMIs, SCADA systems, industrial networks, instrumentation, and control system architecture.
• Lead identification, justification, and implementation of automation projects that improve safety, quality, throughput, reliability, and labor utilization.
• Drive standardization of controls platforms, electrical systems, safety systems, and manufacturing data collection systems throughout the facility.
• Provide escalation-level technical guidance on significant automation and manufacturing technology issues
• Support operations and maintenance teams in improving equipment reliability through controls and automation improvements.
• Develop and maintain equipment documentation, electrical schematics, standards, and specifications.
• Production-capacity expansion projects
• Manufacturing infrastructure improvements
• Equipment lifecycle planning
• Technology investment strategy
• Major modernization programs

Functional Safety Leadership

• Develop long-range engineering investment strategies aligned with business growth objectives.
• Lead machine and process risk assessments utilizing ISO 12100, ISO 13849, ANSI B11, NFPA 79, and applicable corporate safety standards.
• Participate in and support in machine safety audits together with EHS.
• Develop Safety Requirement Specifications (SRS) for new and modified equipment.
• Lead safety validation activities for machine safety systems and safeguarding projects.
• Establish machine safety standards and best practices for the facility, including their incorporation into 6S audits and standards.
• Support Process Safety Management (PSM) initiatives and compliance activities.
• Identify and execute engineering-based risk reduction projects.
• Partner with Safety and Operations teams to improve employee safety and reduce operational risk.
• Ensure new equipment and modifications comply with applicable electrical and machine safety requirements.

Capital Project Management

• Develop and prioritize the facility engineering capital portfolio and long-range modernization plan.
• Develop, justify, and manage automation, controls, and manufacturing technology capital projects.
• Lead projects from concept development through design, procurement, installation, commissioning, and project closeout.
• Develop project scopes, schedules, budgets, resource plans, and business case justifications.
• Coordinate internal resources, contractors, OEMs, integrators, consultants, and vendors.
• Monitor project performance and communicate progress to plant leadership.
• Ensure project completion safely, on schedule, and within approved budgets.
• Maintain a portfolio of active capital and continuous improvement projects.

Asset Modernization & Strategic Planning

• Develop and maintain 3-year, 5-year, and 10-year modernization roadmaps for manufacturing equipment and control systems.
• Evaluate control system obsolescence risks and develop replacement strategies.
• Lead long-term planning for controls, automation, robotics, instrumentation, and manufacturing technology investments.
• Develop automation and technology capital plans aligned with business objectives.
• Identify opportunities to modernize aging equipment and improve operational capability.
• Evaluate emerging technologies and determine applicability to manufacturing operations.

MES, Digital Manufacturing & Industry 4.0

• Partner closely with the Senior MES Engineer to expand manufacturing intelligence and digital manufacturing capabilities.
• Develop strategies to improve utilization of manufacturing data and real-time operational visibility.
• Lead integration of manufacturing equipment with Ignition MES, SCADA, historians, and enterprise systems.
• Define data collection standards and equipment connectivity requirements.
• Support development of dashboards, KPIs, reporting systems, and analytics platforms.
• Collaborate with IT and plant leadership on connected manufacturing and Industry 4.0 initiatives.
• Improve visibility of equipment performance, process stability, production efficiency, and asset utilization through data-driven solutions.

Continuous Improvement & Operational Excellence

• Identify and execute opportunities that reduce waste, improve productivity, increase reliability, and improve manufacturing efficiency.
• Lead root cause analyses of chronic downtime, quality losses, equipment failures, and process variability.
• Utilize Lean Manufacturing, Kaizen, Six Sigma, and continuous improvement methodologies to drive sustainable improvements.
• Develop metrics and performance indicators to measure effectiveness of implemented improvements, or adapt existing 6S or OEE frameworks as applicable.
• Support operational excellence initiatives across manufacturing operations.
• Assist in development of best practices, standards, and procedures that improve plant performance.

Technical Leadership & Collaboration

• Provide strategic leadership for manufacturing technology, automation investments, and plant modernization initiatives.
• Provide technical mentorship to engineers, technicians, supervisors, and operators.
• Support process engineers with instrumentation, automation, controls, and equipment design considerations.
• Train employees in automation systems, machine safety systems, and new technologies.
• Build effective working relationships with all levels of the organization.
• Maintain professional growth through continuing education, industry participation, certifications, and technical training.

Education and Experience

Required

• Bachelor's degree in engineering discipline or equivalent experience.
• Minimum 10 years of experience in industrial automation, controls engineering, manufacturing engineering, project engineering, or related technical leadership roles.
• Minimum 5 years of experience managing capital projects.
• Allen-Bradley ControlLogix expertise.
• Demonstrated experience leading cross-functional engineering and operations initiatives.
• Experience developing project scopes, business cases, schedules, budgets, and capital requests.
• Experience with PLC, HMI, SCADA, and industrial automation systems.
• Experience integrating manufacturing equipment with data collection, MES, or enterprise systems.
• Experience conducting machine safety risk assessments and implementing safeguarding solutions.
• Strong project management, leadership, and organizational capabilities.
• Must be willing and able to work extra hours as needed, to ensure quality and timely completion of deliverables.

Preferred

• Experience in foundry, metals, steel, heavy industrial, automotive, or similar manufacturing environments.
• Ignition SCADA/MES experience.
• Fanuc robotics experience.
• Industrial networking expertise.
• SQL database and manufacturing data systems experience.
• Functional Safety Certification (CMSE, TUV, or equivalent).
• Lean, Six Sigma, or Continuous Improvement Certification.
• ISA-95 or Industrial Digital Transformation experience.

Technical Competencies

• Industrial Automation Systems
• PLC Programming & Architecture
• HMI & SCADA Systems
• Ignition Platform Integration
• Industrial Networking
• Robotics & Motion Control
• Instrumentation & Process Control
• Functional Safety Systems
• Control System Architecture
• Machine Safety Standards
• Manufacturing Data Systems
• MES Integration
• Electrical Systems Design
• Industrial Cybersecurity Fundamentals
• Capital Project Management

Skills/Competencies

• Excellent verbal and written communication skills for collaboration across all organizational levels.
• Strong leadership and mentorship abilities to guide teams and train personnel.
• Excellent organizational skills and attention to detail in managing multiple priorities.
• Ability to thrive in a fast-paced, high-pressure foundry environment.
• Proficient with Microsoft Office Suite or related software.

Physical Demands

While performing the duties of this job, the employee is frequently required to talk or hear; frequently required to stand, walk, or sit; regularly required to use hands to finger, handle, or feel and reach with hands and arms; occasionally required to stoop, kneel, crouch, or crawl. The employee must occasionally lift and/or move up to 35 pounds.

Work Environment

The typical work environment is a standard office setting within a foundry or manufacturing facility. The employee is occasionally required to perform work in a foundry environment with exposure to moving mechanical parts, high temperatures, risk of electrical shock, and moderate noise levels.

Additional Notes

• The Company retains the right to change or assign other duties to this position.
• Proof of US citizenship, nationality, and/or permanent resident status is required to comply with all applicable export and import laws and regulations.
• All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or status as a protected veteran.

All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or status as a protected veteran.

With more than 120 operations and approximately 20,000 employees worldwide, Precision Castparts Corp. is the market leader in manufacturing large, complex structural investment castings, airfoil castings, forged components, aerostructures and highly engineered, critical fasteners for aerospace applications. In addition, we are the leading producer of airfoil castings for the industrial gas turbine market. We also manufacture extruded seamless pipe, fittings, and forgings for power generation and oil & gas applications; commercial and military airframe aerostructures; and metal alloys and other materials for the casting and forging industries. With such critical applications, we insist on quality and dependability - not just in the materials and products we make, but in the people we recruit.

PCC is relentless in its dedication to being a high-quality, low-cost and on-time producer; delivering the highest value to its customers while continually pursuing strategic, profitable growth.

In 2016, Berkshire Hathaway, led by Chairman and CEO Warren E. Buffett, acquired Precision Castparts Corp.