To be honest, I've found that I've been screened *less* as a nonrev. Assuming you're an employee and not a buddy, bring your badge and use that as identification (yes, it's sufficient for security). Many airports also have employee lines that are OK to use, even if you don't work at *that* airport, and they tend to be a little more laid back. As an example, the metal detector at MSP would let me go through with my belt on at the security line a couple years back, whereas when I tried to go through on a normal line it'd beep as soon as I stepped in.
Mig, since you're the most active member with access to AA's system, could you see if it's worth it for this guy to make the drive to ORD?
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