Warehouse Material Flow Engineer Boston - MA - Massachusetts

Mandatory Skills: Warehouse Exp., Automotive

Key Responsibilities (High Level):

- End-to-end warehouse and material flow design

- Buffer analysis and planning

- Material handling equipment evaluation and procurement

- Cart design and procurement

- Lineside and finished goods buffer planning

- Aisle sizing and optimization

Job Description:

- Own the full lifecycle of material flow and process equipment from concept development and detailed engineering design through industrialization, commissioning, and handover to operations.

- Design, develop, and deploy automated and semi-automated material flow systems (AGV, AMR, A VRC, conveyors, robotic cells, lifts, ASRS) that enable safe, efficient, and scalable manufacturing operations.

- Specify mechanical, electrical, and control system requirements, ensuring compliance with factory layout constraints, safety standards, and ergonomic guidelines.

- Develop system architecture, capacity, and throughput models to validate technical feasibility, balance OPEX and CAPEX, and align with factory growth and production strategies.

- Collaborate cross-functionally with Manufacturing, Operations, Controls, Facilities, Process, and Industrial Engineering teams to integrate automation with MES, WMS, and PLC-based control systems.

- Demonstrate advanced material flow and automation design expertise, mastering AMRAGVAtechnologies, conveyance systems, VRCs, docking systems, robotics, and line balancing to optimize throughput and manufacturing flow.

- Lead end-to-end program management, including scope definition, vendor selection, RFQ development, procurement, FATSAT, schedule tracking, budget oversight, and milestone reporting.

- Build and execute Discrete Event Simulation (DES) models using tools like FlexSim to evaluate capacity, material flow, and resource utilization.

- Partner cross-functionally with Operations, Engineering, Supply Chain, and Finance teams to align modeling, simulation, and planning activities.

- Deliver data-driven insights and simulation-based recommendations to enable strategic and operational decision-making across the organization.

- Define and standardize fleet management, path optimization, and traffic control strategies for AGVAMR systems to ensure robust and scalable factory automation.

- Analyze performance data (OEE, throughput, downtime) to identify bottlenecks and drive continuous improvement in flow efficiency, reliability, and automation performance.

- Implement corrective actions and continuous improvement initiatives to enhance uptime, safety, and scalability in high-volume manufacturing environments.

- 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.

What You ll Bring

- Bachelor s or master s degree in Industrial or Mechanical Engineering (or a related technical field).

- 5+ years of experience in manufacturing, automation, or material handling engineering within high-volume or logistics environments.

- Proven expertise in AGV, AMR, A VRC, conveyors, robotics, and ASRS design, integration, and commissioning.

- Strong proficiency in AutoCAD, SolidWorks, and factory simulationflow modeling tools such as FlexSim or equivalent.

- Knowledge of simulation and digital twin tools (FlexSim or equivalent) for flow analysis and predictive optimization.

- Demonstrated ability to lead projects end-to-end from concept and design through installation, commissioning, and production readiness.

- Skilled in program management, including scope, schedule, budget control, and vendor coordination across complex manufacturing projects.

- Solid understanding of controls integration (PLCMESWMS) and industrial safety standards (ANSIISOIEC).

- Strong knowledge of Lean Manufacturing, PFEP (Plan for Every Part), Just-in-Time (JIT), and continuous improvement methodologies.

- Proven ability to interpret and act on manufacturing KPIs (OEE, throughput, yield, downtime) to drive measurable efficiency gains.

- Exceptional analytical, communication, and leadership skills, with the ability to align cross-functional teams toward common goals.

Preferred Qualifications

- Proficiency in data analytics and visualization tools such as Python, SQL, Power BI, or Tableau for equipment performance monitoring and reporting.

- Exposure to IoT-enabled automation systems for real-time equipment monitoring and performance tracking.

- Strong problem-solving mindset and continuous improvement orientation.

- Demonstrated project management experience including budgeting, scheduling, and vendor collaboration.

- Six Sigma Green Belt or Lean Manufacturing certification.

- Experience in battery manufacturing, energy storage, or other high-tech manufacturing environments.