Job DescriptionThe Materials Flow Engineer will lead and oversee multiple complex projects focused on optimizing material flow, material storage, and advanced manufacturing processes across multi-site operations. This role serves as a technical authority responsible for designing and implementing intelligent material flow systems, leading new product introduction programs, supporting product transfers, and driving process improvements and capital projects to support growth and operational excellence. The specialist will interact directly with Design Engineering, Program Managers, Logistics, Purchasing, and Operations Teams to coordinate and execute manufacturing milestones and deliverables while ensuring the right materials are delivered to the right place, at the right time, with minimal waste. This position requires deep technical expertise in advanced manufacturing engineering principles, lean methodologies, and digital manufacturing technologies.
RESPONSIBILITIES
Manufacturing Engineering & Technical Leadership
- Work closely with Line of Business Leaders to ensure manufacturing plans are aligned to Product Roadmaps and long-term strategic growth objectives.
- Lead, develop, and implement comprehensive manufacturing plans for assigned new products according to the NPDI program, applying Design for Manufacturability (DFM) and Design for Assembly (DFA) principles.
- Lead and provide direct support for plant-to-plant product transfers and new product development programs, ensuring technical feasibility assessments and manufacturing readiness reviews are completed at each program gate.
- Identify, justify, pilot, and commission Advanced Manufacturing technologies, processes, equipment, and practices, including capital projects that support Growth, NPDI, Product Transfers, Technical Capacity, and Footprint.
- Responsible for the execution of Manufacturing Readiness Checklists and deliverables of the NPDI Process, including process capability studies and failure mode and effects analysis (FMEA).
- Leader for Manufacturing Prototype builds along with the local operations team to achieve 2-week lead time, applying rapid prototyping methodologies and iterative build strategies.
- Implement best manufacturing practices for existing processes and provide multi-site advanced manufacturing engineering support, including process standardization and technical documentation.
- Assist with business-critical capital projects including facility planning, layout optimization using simulation tools, and detailed cost justification with ROI analysis.
- Apply time and motion studies, ergonomic assessments, and workstation design principles to optimize operator efficiency and safety.
- Develop and maintain technical engineering standards, work instructions, and process control plans to ensure consistency across manufacturing sites.
- Lead root cause analysis (RCA) and corrective action processes for manufacturing-related issues using structured problem-solving methodologies such as 8D, A3, and Fishbone analysis.
Material Flow & Storage Optimization
- Analyze, design, and implement optimized material flow strategies using simulation modeling and digital twin technologies to ensure end-to-end synchronization across suppliers, internal operations, and warehouse environments.
- Collaborate with cross-functional teams including Production, Logistics, Engineering, and Purchasing to align material flow systems with business goals and production scheduling requirements.
- Identify bottlenecks and inefficiencies in current material flow processes and propose data-driven, quantified solutions with measurable impact on throughput and cost reduction.
- Partner closely with the warehousing team to evaluate space utilization using slotting optimization techniques, streamline storage strategies, and implement best practices that support lean manufacturing principles.
- Support implementation of automated material handling systems (AMHS), including Automated Guided Vehicles (AGVs), conveyor systems, and robotic pick-and-place solutions, as well as digital transformation and Industry 4.0 initiatives focused on connected and intelligent material handling.
- Continuously monitor and analyze KPIs related to materials movement such as throughput, cycle time, delivery performance, and inventory accuracy, using real-time data dashboards and analytics platforms.
- Design and implement supermarket pull systems and kanban replenishment strategies to synchronize material flow with production demand.
- Develop standardized workflows and Standard Operating Procedures (SOPs) to ensure materials move efficiently from receiving to point-of-use.
- Apply warehouse management system (WMS) capabilities to improve inventory visibility, traceability, and accuracy across the facility.
- Ensure compliance with safety, ergonomic, and environmental standards in all flow system designs, incorporating ergonomic risk assessments and material handling equipment specifications.
- Lead capacity planning and load balancing analyses to ensure material flow systems can scale with production growth.
Advanced Engineering & Digital Manufacturing
- Lead the evaluation and implementation of Industry 4.0 and Smart Manufacturing technologies, including IoT-enabled material tracking, RFID systems, and real-time location systems (RTLS).
- Develop value stream maps (VSM) for current and future states, identifying waste elimination opportunities and quantifying improvement potential across the entire material flow value chain.
- Apply simulation and modeling tools (e.g., Arena, FlexSim, or equivalent) to validate material flow designs before physical implementation.
- Drive data analytics initiatives to identify trends, predict material shortages, and optimize replenishment cycles using predictive analytics and machine learning tools.
- Support the integration of ERP/MRP systems (Oracle, SAP) with shop floor execution systems to enable real-time material visibility and automated replenishment triggers.
- Develop and implement Overall Equipment Effectiveness (OEE) improvement strategies tied to material availability and flow performance.
Continuous Improvement
- Support Vertiv manufacturing operations using standard processes, equipment, and manufacturing methods, driving consistency and repeatability across sites.
- Lead and participate in continuous improvement initiatives such as Kaizen events, Lean Manufacturing projects, and Six Sigma DMAIC projects targeting material flow and storage optimization.
- Coordinate the development and enforcement of global manufacturing standards and technology leadership, ensuring best practices are documented and deployed across all relevant sites.
- Mentor and coach junior engineers and operations team members on advanced manufacturing principles, lean tools, and continuous improvement methodologies.
- Develop and track improvement roadmaps with clearly defined milestones, resource requirements, and expected financial benefits.
QUALIFICATIONS
Minimum:
- Bachelor's degree in industrial engineering, Mechanical Engineering, Supply Chain Management, Business Operations Management, or related field.
- 5-6 years of experience in advanced manufacturing, materials flow engineering, supply chain logistics, or lean manufacturing.
Preferred:
- Master's degree (MSME/IE/MBA) with 6 or more years of Advanced Manufacturing experience.
- Lean Manufacturing and Six Sigma formal training or certifications (Green Belt or Black Belt preferred).
- Experience with simulation and modeling software for material flow and facility layout design.
- Familiarity with Industry 4.0 technologies, including IoT, RFID, AGVs, and digital twin platforms.
Requirements:
- Extensive knowledge of formalized Advanced and Lean Manufacturing applications, including value stream mapping, takt time analysis, inventory decoupling strategies, kanban systems, and pull-based replenishment.
- Extensive experience in New Product Development, Product Transfers, and Material Flow optimization across multi-site environments.
- Strong knowledge of manufacturing process engineering principles, including DFM/DFA, FMEA, process capability analysis, and control plans.
- Experience with ERP/MRP systems (Oracle, SAP) for integrated planning and material control, including shop floor integration.
- Proficiency in data analysis tools such as Excel (advanced), Power BI, Minitab, or equivalent analytical platforms.
- Excellent vertical communication, interpersonal, and motivation skills, with the ability to present technical findings to senior leadership.
- Demonstrated ability to think creatively; ability to coach, train, facilitate, and lead teams effectively in a transformational work environment.
- Demonstrated strong project management and technical skills; analytical skills; PC skills.
- Demonstrated ability to achieve results through team building and teamwork.
- Analytical mindset with strong problem-solving skills and structured thinking.
PHYSICAL & ENVIRONMENTAL DEMANDS
- The role is primarily based in a manufacturing facility, requiring regular site visits and interaction with production teams.
- Required to wear personal protective equipment (PPE) and adhere to safety protocols.
- The role involves extended periods of sitting in front of a computer.
- Occasional standing or walking may be required during meetings, presentations, or site visits.
TIME TRAVEL REQUIRED
- 25% travel to different plant locations and suppliers.
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