Project Engineer
Project Engineer. They will be in a key operations role responsible for driving cross-functional projects that improve quality, reduce cost, and increase production efficiency across OSG's multi-plant network. Reporting directly to the Chief Operating Officer, this individual will serve as a subject matter expert in lean methodologies and continuous improvement, owning projects from initiation through implementation and sustained results. The role requires a self-directed professional who can operate effectively in a fast-paced transactional print and mail environment, manage multiple concurrent workstreams, and deliver measurable outcomes.
Key Responsibilities
Project Planning & Management- Develop, maintain, and manage detailed project plans for operations improvement, capital, and quality initiatives
- Define project scope, timelines, milestones, resource requirements, and success metrics
- Track project status and proactively identify and resolve schedule, resource, or risk issues
- Communicate project progress to leadership through structured updates and steering reviews
- Manage multiple projects simultaneously across plants, ensuring alignment to company priorities
Lean Six Sigma & Quality Improvement- Lead and facilitate Lean Six Sigma (LSS) projects targeting defect reduction, SLA improvement, and cost elimination
- Apply DMAIC and other structured problem-solving frameworks to root cause analysis and corrective actions
- Conduct process capability analysis, measurement system analysis (MSA), and statistical process control (SPC)
- Partner with plant quality teams to develop and implement Quality Improvement Plans (QIPs) and standard work
- Drive kaizen events and value stream mapping sessions across Carol Stream and other OSG facilities
- Track quality metrics and produce data-driven reporting to leadership on CII trends and quality performance
Productivity & Cost Efficiency- Identify and execute labor and materials cost reduction opportunities aligned to AOP and financial targets
- Analyze plant-level P&L data to pinpoint cost drivers and develop structured action plans to close gaps
- Benchmark production output, machine throughput, and staffing models to identify efficiency improvement opportunities
- Develop and track productivity KPIs including OEE, uptime/downtime, waste rates, and cost per unit metrics
- Collaborate with plant leadership to implement solutions that reduce headcount dependency without compromising output or quality
Cross-Plant & Travel Responsibilities- Travel frequently to OSG plant locations including but not limited to Carol Stream - IL , Carlstadt - NJ, Milwaukee - WI, Tempe - AZ, and Mount Airy - NC
- Serve as an on-site operations resource during project implementation phases at remote plants
- Build strong working relationships with plant managers, supervisors, and front-line operators across sites
Additional Responsibilities- Support capital equipment evaluation and justification, including ROI analysis and implementation planning for press replacements or upgrades
- Participate in client-impacting incident (CII) reviews and drive root cause investigations and corrective action implementation
- Document standard operating procedures (SOPs), process flows, and operational playbooks
- Assist in the development of management operating system (MOS) tools including dashboards, scorecards, and reporting frameworks
Required Qualifications
- Bachelor's degree in Industrial Engineering, Mechanical Engineering, Manufacturing Engineering, or a related field
- 2+ years of experience in operations, manufacturing, or production engineering roles
- Lean Six Sigma Green Belt certification required; Black Belt preferred
- Demonstrated success managing cross-functional projects from initiation to closure with measurable results
- Proficiency in data analysis tools including Excel (advanced), Power BI, or similar platforms
- Strong written and verbal communication skills; ability to present data and recommendations clearly to senior leadership
- Ability and willingness to travel up to 40-50% of the time to OSG plant locations
- Must be based in or willing to relocate to the Carol Stream, IL area
Benefits:- Health Insurance (EPO & HRA options)
- Dental Insurance
- Vision Insurance
- Short & Long Term Disability
- Flexible Spending Accounts
- Life Insurance
- Accident & Critical Illness Insurance
- Company 401(k) Matching Contribution
- Paid Time Off (PTO)
- Employee Assistance Program (EAP)
