Lean Material Flow Specialist

Lean Material Flow Specialist

The Lean Material Flow Specialist is directly responsible and accountable for the tactical and real-time execution of lean material flow within a chemical processing environment. This includes inventory kitting, staging, replenishing, returning, and direct digital/material accountability from warehouse through line-side, changeover, and end-of-run. The Specialist acts as the subject matter expert on inventory accuracy, material readiness, and buffer management, enabling higher operator value-add time and improved reliability all in compliance with PSM, OSHA, HazCom and facility protocols.

Essential Duties:

• Review production schedules, batch records, and inventory data to prepare kitting and staging requirements for raw materials, packaging, and consumables.
• Pick, kit, label, stage, and issue materials to production lines to ensure accurate, timely availability.
• Replenish line-side, staging, and buffer inventory based on production demand and changing priorities.
• Reconcile physical and system inventory in SAP/ERP; investigate, escalate, and help resolve discrepancies affecting production readiness.
• Support changeovers and machine setup by aligning staged materials to production needs to reduce downtime.
• Manage returns, scrap, empties, and by-products to maintain organized work areas, material traceability, and compliance.
• Collaborate with Material Handlers and Warehouse Manager to coordinate material movement between warehouses, secondary storage, and production areas to maintain continuous flow.
• Monitor shortages, stockouts, and bottlenecks; communicate proactively with production, warehouse, and shift leadership.
• Maintain accurate material transactions, labeling, and documentation to support inventory control and regulatory standards.
• Assist with cross-shift, weekend, and contingency coverage plans, while supporting 5S and continuous improvement in staging and material flow processes.

Success Criteria:

• Material Flow Reliability: ?98% on-time completion of workstation replenishment with zero unplanned stockouts at point-of-use stations.
• Safety & Compliance Excellence: Zero incidents, spills, exposures, or regulatory findings; 100% adherence to PSM, OSHA, HazCom, RCRA, DOT, and spill prevention protocols.
• Inventory & Pull System Accuracy: ?99% POU inventory match during audits.
• Waste & Contamination Control: Zero accumulation of empties/hazardous waste at workstations and zero cross-contamination events.
• Operator Support Effectiveness: ?95% reduction in operator material-fetching interruptions (via audits/feedback); on-time assistance for ?95% of changeovers.

Qualifications:

• High school diploma or equivalent; technical/chemical-related certification preferred.
• 12 years in chemical manufacturing, material handling, or production support; hazardous materials experience a plus.
• Knowledge of Lean principles (JIT, Kanban, waste reduction) and regulated process industries.
• Strong time management, reliability, and ability to follow precise routes/schedules.
• Physical ability to walk extensively, handle carts/tuggers/dollies, and lift up to 50 lbs while wearing PPE (respirators, suits, etc.).
• Safety-focused mindset with attention to detail, quality, and regulatory compliance.
• Good communication/teamwork; basic ERP/scanner skills.

Work Environment /Physical Demands:

Work Environment: Primarily on the chemical production floor with high mobility across reactors, mixers, filling lines, storage areas, and waste zones; exposure to typical manufacturing conditions including noise, chemical odors, varying temperatures, potential hazardous atmospheres, and strict PPE-required areas (e.g., respirators, protective clothing, gloves); adherence to PSM, OSHA, HazCom, RCRA, and facility safety protocols is mandatory at all times.

Physical Demands: Extensive walking and standing for most/all of the shift while following replenishment routes; frequent pushing/pulling of carts, tuggers, drum dollies, or material handling equipment; lifting, carrying, and moving loads up to 50 lbs (e.g., containers, drums, supplies); bending, stooping, and reaching to handle materials or replenish stations; sustained physical activity to maintain pace and reliability in a fast-moving, safety-critical setting.

Additional Considerations: Must wear full required PPE continuously; ability to respond quickly to alerts or needs without compromising safety; role requires good balance, stamina, and dexterity for precise handling of chemicals and equipment to prevent spills, exposures, or cross-contamination.