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