Material Flow Engineer

Job Description

Role: Material Flow Engineer

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Location: Pittsburgh, PA (Onsite)

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Mode: Fulltime only

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Experience level: 5-18 Years

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Old submission format.

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Must-Have Skills:

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• Ownership of the complete warehouse design and material flow operations.
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• Material handling equipment evaluation and procurement
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• Cart design and procurement
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• Lineside and finished goods buffer planning
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• Aisle sizing and optimization
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• Strong expertise in material handling systems including AGV, AMR, ASRS, conveyors, VRCs, robotics, and warehouse automation.
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• Hands-on experience in factory layout design, aisle sizing, cart/rack design, capacity planning, throughput analysis, and line balancing.
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• Proficiency in FlexSim (or equivalent), Discrete Event Simulation (DES), Digital Twin modeling, and material flow optimization.
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• Strong knowledge of AutoCAD, SolidWorks, PLC/MES/WMS integration, and industrial safety standards.
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• Proven ability to lead projects from concept through procurement, vendor management, commissioning (FAT/SAT), and production handover in high-volume manufacturing environments.
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Detailed Job Description:

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What You’ll Do

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• Own the full lifecycle of material flow and process equipment — from concept development and detailed engineering design through industrialization, commissioning, and handover to operations.
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• Design, develop, and deploy automated and semi-automated material flow systems (AGV, AMR, AGC, VRC, conveyors, robotic cells, lifts, ASRS) that enable safe, efficient, and scalable manufacturing operations.
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• Specify mechanical, electrical, and control system requirements, ensuring compliance with factory layout constraints, safety standards, and ergonomic guidelines.
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• Develop system architecture, capacity, and throughput models to validate technical feasibility, balance OPEX and CAPEX, and align with factory growth and production strategies.
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• Collaborate cross-functionally with Manufacturing, Operations, Controls, Facilities, Process, and Industrial Engineering teams to integrate automation with MES, WMS, and PLC-based control systems.
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• Demonstrate advanced material flow and automation design expertise, mastering AMR/AGV/AGC technologies, conveyance systems, VRCs, docking systems, robotics, and line balancing to optimize throughput and manufacturing flow.
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• Lead end-to-end program management, including scope definition, vendor selection, RFQ development, procurement, FAT/SAT, schedule tracking, budget oversight, and milestone reporting.
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• Build and execute Discrete Event Simulation (DES) models using tools like FlexSim to evaluate capacity, material flow, and resource utilization.
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• Partner cross-functionally with Operations, Engineering, Supply Chain, and Finance teams to align modeling, simulation, and planning activities.
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• Deliver data-driven insights and simulation-based recommendations to enable strategic and operational decision-making across the organization.
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• Define and standardize fleet management, path optimization, and traffic control strategies for AGV/AMR systems to ensure robust and scalable factory automation.
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• Analyze performance data (OEE, throughput, downtime) to identify bottlenecks and drive continuous improvement in flow efficiency, reliability, and automation performance.
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• Implement corrective actions and continuous improvement initiatives to enhance uptime, safety, and scalability in high-volume manufacturing environments.
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• Serve as a technical mentor and subject-matter expert (SME) in automation and material handling, advising leadership on technology roadmaps and long-term automation strategy.
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What You’ll Bring

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• Bachelor’s or master’s degree in industrial or mechanical engineering (or a related technical field).
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• 5+ years of experience in manufacturing, automation, or material handling engineering within high-volume or logistics environments.
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• Proven expertise in AGV, AMR, AGC, VRC, conveyors, robotics, and ASRS design, integration, and commissioning.
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• Strong proficiency in AutoCAD, SolidWorks, and factory simulation/flow modeling tools such as FlexSim or equivalent.
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• Knowledge of simulation and digital twin tools (FlexSim or equivalent) for flow analysis and predictive optimization.
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• Demonstrated ability to lead projects end-to-end — from concept and design through installation, commissioning, and production readiness.
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• Skilled in program management, including scope, schedule, budget control, and vendor coordination across complex manufacturing projects.
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• Solid understanding of controls integration (PLC/MES/WMS) and industrial safety standards (ANSI/ISO/IEC).
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• Strong knowledge of Lean Manufacturing, PFEP (Plan for Every Part), Just-in-Time (JIT), and continuous improvement methodologies.
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• Proven ability to interpret and act on manufacturing KPIs (OEE, throughput, yield, downtime) to drive measurable efficiency gains.
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• Exceptional analytical, communication, and leadership skills, with the ability to align cross-functional teams toward common goals.
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Preferred Qualifications

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• Proficiency in data analytics and visualization tools such as Python, SQL, Power BI, or Tableau for equipment performance monitoring and reporting.
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• Exposure to IoT-enabled automation systems for real-time equipment monitoring and performance tracking.
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• Strong problem-solving mindset and continuous improvement orientation.
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• Demonstrated project management experience including budgeting, scheduling, and vendor collaboration.
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• Six Sigma Green Belt or Lean Manufacturing certification.
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• Experience in battery manufacturing, energy storage, or other high-tech manufacturing environments.
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