Senior Project Engineer Jobs in Pleasant Prairie, WI

The Project Engineer leads new product development and launch activities from concept through production readiness for automotive and precision-engineered components. This role manages complex programs, coordinates cross-functional teams, and ensures robust processes for injection molding, metal stamping, and electric motor-related components. The Project Engineer plays a key role in technical evaluations, tooling support, and continuous improvement to optimize product performance, quality, and cost.

• Lead new product development and launch activities from initial concept through production readiness for automotive and precision-manufactured components.
• Manage project timelines, deliverables, risks, and cross-functional coordination to ensure successful execution of multiple programs.
• Support Advanced Product Quality Planning (APQP) activities, Production Part Approval Process (PPAP) submissions, engineering changes, corrective actions, and continuous improvement initiatives.
• Lead design reviews, feasibility studies, and manufacturability evaluations to ensure robust product and process design.
• Plan and execute Design of Experiments (DOE) activities to optimize product and process performance.
• Coordinate prototype development using 3D printing, rapid tooling, machining, and related prototyping methods.
• Support tooling design, tooling tryouts, process validation, and production launch activities for molding and stamping operations.
• Work closely with production teams to coordinate the launch of new business and ensure smooth transition from development to full-scale manufacturing.
• Drive value engineering initiatives, product improvements, and cost-reduction projects to enhance competitiveness and profitability.
• Prepare technical evaluations, feasibility assessments, and cost analyses for new and existing programs to support business decisions.
• Collaborate with suppliers and vendors on tooling, materials, automation, testing, and equipment requirements to ensure capability and quality.
• Support development of automotive injection molded components, over-molded and insert-molded parts, lamination stacks, and lead frame components for electrical applications.
• Provide technical support to customers, sales, quality, and manufacturing teams, addressing product and process-related questions and issues.
• Build and maintain strong working relationships with automotive original equipment manufacturers (OEMs), Tier suppliers, and key customers.
• Perform hands-on evaluations of molds, tooling, fixtures, machinery, and manufactured components to verify performance and identify improvement opportunities.
• Conduct visual inspection of parts, tooling, drawings, and product features, including identifying defects and dimensional variations.
• Support and champion continuous improvement and best practices in product development, manufacturing engineering, and project management.

• Experience in product development, manufacturing engineering, or project engineering within an automotive or precision manufacturing environment.
• Knowledge of injection molding processes, including tooling design, process validation, and production launch for molded components.
• Knowledge of metal stamping operations and associated tooling and process requirements.
• Practical understanding of manufacturing process validation and quality assurance methodologies.
• Experience with APQP (Advanced Product Quality Planning) and PPAP (Production Part Approval Process) in an automotive or similar environment.
• Experience with DOE (Design of Experiments) and continuous improvement methodologies.
• Strong project management skills, including the ability to manage timelines, deliverables, risks, and cross-functional coordination.
• Strong communication skills, with the ability to present technical information clearly to internal teams, customers, and suppliers.
• Demonstrated cross-functional leadership capabilities and ability to influence without direct authority.
• Ability to manage multiple projects simultaneously in a fast-paced environment.
• Technical aptitude to perform hands-on evaluations and visual inspections of parts, tooling, fixtures, and machinery.
• Ability to travel to customer, supplier, and manufacturing locations as required.

• Bachelor’s degree in Engineering or a related technical field is preferred.
• Experience supporting electric motor or precision-engineered component applications is a plus.
• Background in the automotive industry, including working with automotive OEMs and Tier suppliers, is highly beneficial.
• Experience with value engineering, cost-reduction initiatives, and product improvement projects.
• Familiarity with rapid prototyping methods such as 3D printing, rapid tooling, and machining.
• Ability to build strong working relationships with customers, suppliers, and internal stakeholders.
• Strong analytical and problem-solving skills, including the ability to conduct feasibility assessments and cost analyses.

This role operates in both office and manufacturing environments, offering a blend of technical design work and hands-on engagement on the production floor. The Project Engineer regularly interacts with molds, tooling, fixtures, machinery, and manufactured components, and performs visual inspections to identify defects and dimensional variations. The position may require occasional lifting and carrying of up to 25 pounds during evaluations or production support activities. Travel to customer, supplier, and manufacturing locations is required as needed to support program launches, tooling reviews, and technical collaboration. The environment is fast-paced and collaborative, with close coordination among engineering, production, quality, sales, and supplier teams to bring new automotive and precision-engineered products successfully to market.

This is a Contract to Hire position based out of Kenosha, WI.

The pay range for this position is $48.07 - $57.69/hr.

Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors.

Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following: • Medical, dental & vision • Critical Illness, Accident, and Hospital • 401(k) Retirement Plan – Pre-tax and Roth post-tax contributions available • Life Insurance (Voluntary Life & AD&D for the employee and dependents) • Short and long-term disability • Health Spending Account (HSA) • Transportation benefits • Employee Assistance Program • Time Off/Leave (PTO, Vacation or Sick Leave)

This is a fully onsite position in Kenosha,WI.

This position is anticipated to close on Aug 31, 2026.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email actalentaccommodation@actalentservices.com for other accommodation options.

San Francisco Fair Chance Ordinance: Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.

Massachusetts Lie Detector: It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.

Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.