Ford Motor Company

Material Handling Engineer (KTP)

Ford Motor Company • $96K — $162K *
Louisville, KY 40214In-Person
Manufacturing & Automotive
5 - 7 years of experience
Today
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Job Overview by Ladders

Qualifications

  • Bachelor's Degree required
  • 5+ years in Material Planning & Logistics
  • Experience in end-to-end Material Flow Management
  • Proficiency in Microsoft Office, AutoCAD, ERP/SAP systems
  • Lean manufacturing knowledge preferred

Responsibilities

  • Lead material flow from receiving to shipping
  • Manage Engineering Change Management processes
  • Drive performance improvements through kaizen initiatives
  • Implement automation solutions for material handling
  • Analyze material handling and optimize plant layouts
  • Ensure system readiness for new programs and changes
  • Enforce safety standards and resource planning

Benefits

  • Health insurance options
  • Retirement plan contributions
  • Paid time off and holidays
  • Professional development opportunities
  • Employee discounts and perks
Full Job Description
Job Description

In this position...

You will manage the flow and movement of materials through manufacturing facilities to support production operations.

Responsibilities

What you'll do...

  • Lead end-to-end material flow from receiving docks to point-of-use and shipping for direct and indirect materials. Design and optimize lean material delivery systems (line-side delivery, warehouse marketplace, kitting, sequencing). Manage inventory strategy and PFEP (Plan for Every Part) including storage, flow paths, and capacity planning.
  • Own the end-to-end Engineering Change Management & Control (ECM/ECC) process for MP&L, ensuring alignment with plant and corporate change management systems. Lead cross-functional coordination (Engineering, Purchasing, Suppliers, Operations) for all part, supplier, and process changes. Develop and execute change readiness plans (inventory burn-down, phase-in/phase-out, cutover timing, obsolescence mitigation).
  • Drive performance improvements through structured problem solving and kaizen. Lead cost savings initiatives, including labor efficiency, inventory reduction, and space optimization. Apply root cause problem solving (A3, 8D, DMAIC) to eliminate waste and variation
  • Implement and support automation solutions (AGVs, AMRs, ASRS, smart conveyance)
  • Analyze and improve material handling methods, equipment utilization, and labor balancing. Conduct cycle time analysis, bottleneck identification, and throughput optimization. Design plant layouts, flow paths, and material presentation using CAD and simulation tools. Lead ergonomic assessments and workstation design to improve safety and productivity
  • Ensure system readiness (ERP/SAP updates, BOM accuracy, routings, packaging specs, labeling, and traceability requirements). Drive launch and program integration, ensuring material flow readiness for new programs, engineering changes, and model year transitions. Identify and mitigate change-related risks (line disruption, premium freight, inventory write-offs, supplier readiness gaps)
  • Enforce safety standards, ergonomics, and 5S discipline across all material handling operations. Manage resource planning (labor, equipment, space) to meet production requirements.
  • Strong capability in capacity modeling and constraint-based planning. Advanced proficiency in Excel, Power BI, simulation tools, and CAD (AutoCAD or similar)
  • Understanding of launch management and program readiness (APQP, PPAP impact to MP&L). Experience integrating automation with labor strategy (human-machine balance)
  • Candidates must possess full flexibility and willingness to operate in a fast-paced, high-demand environment and a strong commitment to supporting team success during launches and critical business needs
  • Provide engineering support for material flow process; document standards and procedures, provide training, overall adherence and maintenance to ensure materials are available in designated stock, markets and line locations throughout the facility.
  • Work with Planning & Inventory Control, Production, Material Handlers, and Supply Chain to ensure robust policies are available and practiced and strive for continuous improvement.
  • Apply technical expertise, commensurate with formal training and limited job experience, in the development of material flow processes.
  • Design and/or develops material flow processes and equipment.
  • Recommend changes to increase safety, reduce costs, improve quality and optimize efficiency.
  • Participate in plant layout activities.
  • Develop floor space analyses to confirm storage requirements and recommend practical solutions where required.
  • Assist in qualifying manual and powered material handling equipment requirements
  • Work to improve material flow and manage materials and inventory consistent with Lean principles.
  • Lay out market, sequencing, and kitting areas to facilitate material handling, process flow, space utilization, and labor.
  • Define and manages in-plant storage and call systems to maintain inventories; assists to define appropriate goals and metrics for proper material control.
  • Provide vehicle and pedestrian flow/congestion/safety analyses and recommend practical solutions where required.
  • Interact on a regular basis with other functional groups and vendors on technical and/or administrative matters.
  • Work with Production, Material Handling, and Plant Safety Teams, Supply Chain, Quality, Material Logistics, Industrial Engineering, Ergonomic Engineering, Civil Engineering, Vehicle Manufacturing, Body Construction Engineering, and other engineering departments.
  • Prepare detailed plans, generally spanning several months, vital to complete assigned projects.
  • Develop and approves schedule milestones.
  • Develop and coordinate labor, facility and equipment requirements for projects
  • Propose alternate plans for economic evaluation.
  • Administer technical procedures including process and work procedures.
  • Implement industrial engineering systems and processes (forecast cost data, capacity, establish shop floor control systems, and ensure containment of material movement within floor space).
  • Initiate all inbound packaging approval including efficiency cost savings projects to optimize packaging density.
  • A key aspect of the role will be leading continuous improvement initiatives for returnable container packaging systems. This includes increasing pack density to optimize freight utilization, warehouse efficiency, and labor costs; reducing container and tooling costs through design optimization, standardization, and the adoption of emerging technologies; and enhancing part protection, functionality, durability, and overall packaging performance throughout the supply chain. The engineer will also support campaign and field activities related to container quality concerns, repair requirements, and performance issues. In addition, the position will play a critical role in advancing Packaging Engineering by researching, evaluating, and implementing innovative technologies, materials, processes, and best practices that improve operational efficiency and packaging effectiveness


Qualifications

You'll have...

  • Bachelor's Degree
  • 5 or more years of experience in Material Planning & Logistics end to end Material Flow Management.

Even better, you may have...
  • Bachelor's Degree in Engineering
  • Certifications associated with Material Handling Automation
  • Professional Recognitions and Awards reflecting accomplishments
  • Demonstrated experience working with all levels of the organization
  • Experience working collaboratively on teams and driving
  • Demonstrated leadership behaviors combined with outstanding interpersonal, teambuilding, and communication skills
  • Experience working or running production in a manufacturing plant environment
  • Tenure working in the automotive industry
  • Microsoft Office (Excel/Word/PowerPoint/Outlook/Access)
  • Knowledge of AutoCAD
  • Validated functional expertise in material flow
  • Strong understanding of lean material flow strategies & lean manufacturing processes


You may not check every box, or your experience may look a little different from what we've outlined, but if you think you can bring value to Ford Motor Company, we encourage you to apply!

This position is a salary grade 8 and ranges from $96,720-162,120.

For more information on salary and benefits, click here: https://fordcareers.co/GSR

Visa sponsorship is not available for this position.

Candidates for positions with Ford Motor Company must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire.

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About Ford Motor Company

Ford Motor Company manufactures or distributes automobiles in addition to offering financial services. The company sells to dealerships for retail sales, and for sale to fleet customers, including commercial fleet customers, daily rental car companies, and governments. Ford’s vehicle portfolio includes automobiles, buses, tractors, and trucks. Retail financing includes retail installment sale contracts for new and used vehicles, and direct financing leases for new vehicles to retail customers, government entities, daily rental car companies, and fleet customers. Finance receivables in the non-consumer portfolio include products offered to automotive dealers. Ford’s environmental initiatives include compressed natural gas, flexible fuel vehicles, electric drive vehicles, Hydrogen, PC power management, and so on. Ford Motor Company was founded by Henry Ford in 1903 and is headquartered in Dearborn, Michigan.

Ford Motor Company Careers

Join the dynamic team at Ford Motor Company, a global leader in automotive innovation and manufacturing. At Ford, we are committed to driving human progress by providing outstanding vehicles and mobility solutions. This is an exciting time to become part of our inclusive team, where job opportunities abound and growth is not just a possibility, but a promise.

Work You’ll Do

At Ford Motor Company, you will collaborate with some of the brightest minds in the industry. Our professionals are at the forefront of automotive technology, leading projects that redefine transportation and sustainability. With a culture rooted in continuous improvement and respect for all, Ford offers a workplace where leadership, diversity training, and innovation are part of everyday life.

Join Our Market-Leading Team

Ford’s commitment to excellence is why we are a leader in the automotive sector. We offer a variety of career paths, from engineering to marketing, all designed to foster professional and personal growth. Our team benefits from Ford’s commitment to professional development and networking opportunities, ensuring that every team member can reach their full potential.

Innovative Work

Engage in work that makes a difference. Ford Motor Company is pioneering developments in electrification, autonomous vehicles, and smart mobility solutions. Our team of over 190,000 employees worldwide is dedicated to crafting experiences that improve the way the world moves.

Be Part of a Great Team

Working at Ford means more than just having a job; it means being part of a global family. Our culture promotes teamwork, integrity, and respect—values that underpin everything we do. We believe in nurturing a diverse and inclusive environment where every employee can thrive.

Future-Proof Your Career

Ford Motor Company is not just a great place to work; it’s a place to build a lasting career. Our employees enjoy competitive benefits, comprehensive health care, and retirement plans that rank among the best in the industry. We support career advancement through extensive training programs and hands-on experience in the latest automotive technologies.

Explore Job Opportunities and Internships

Whether you’re a seasoned professional looking for your next challenge or a student interested in an internship, Ford has opportunities that will harness your skills and ignite your ambition. Our hiring process is straightforward and respectful, designed to match your skills and passions with the right position.

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Join Our Team Search open positions that match your skills and interests. We look for passionate, curious, creative, and solution-driven team players. Ready to start your journey with Ford? Prepare your resume, sharpen your interview skills, and become part of a company that’s building the future of transportation.

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Learn more about Ford Motor Company
Size
183,000 employees
Market Cap
$44.8 billion
Industry
Manufacturing & Automotive
Net Income
-$1.2 billion
Founded
1903
5 Year Trend
-2.1%
Revenue
$127.1 billion
NASDAQ
F
* Ladders Estimates

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