Job Title: Converting Line Design & Systems Engineering Lead

Location: Saint Paul, MN
Experience: 8–20 Years
Employment Type: Full-Time

Job Summary

We are seeking an experienced Converting Line Design & Systems Engineering Lead to lead manufacturing systems engineering, converting line design, process planning, workstation design, material flow optimization, and production line simulation.

The ideal candidate will have strong expertise in converting and web-processing operations, manufacturing line layout, Bill of Process (BOP), throughput planning, line-side storage, material replenishment, tooling, inspection aids, and equipment integration. The role requires close collaboration with CAD design engineers, simulation specialists, automation teams, equipment suppliers, line builders, and plant leadership to develop efficient, safe, and scalable manufacturing solutions.

Candidates should have experience providing engineering inputs for material flow simulation, discrete-event simulation, ergonomics simulation, automation, controls, plant IT integration, and equipment certification. Exposure to AI/GenAI is an advantage but is not mandatory.

Must-Have Technical Skills

1. Manufacturing Systems Engineering & Converting Processes

• Strong manufacturing systems engineering competency, preferably at an advanced or E3-level capability.

• Expertise in converting line design, manufacturing process planning, and Bill of Process (BOP) development.

• Understanding of converting operations, including:

  • Unwinding, splicing, threading, and web handling

  • Web tension control and slitting

  • Coating, curing, and cutting

  • Attaching and related assembly operations

  • Primary, secondary, and tertiary packaging

• Ability to design production lines with the appropriate number of stations to meet throughput and cycle-time targets.

• Experience defining station-level processes, production sequences, and line balancing requirements.

2. Line Layout & Workstation Design

• Manufacturing line layout design and optimization.

• Workstation design, including ergonomics, line-side storage, and operator access.

• Design of line-side storage trolleys, material presentation systems, and part-loading aids.

• Material handling equipment (MHE) selection and design.

• Design of conveying systems, including conveyor type, layout, speed, and capacity.

• Development of error-proofing mechanisms, process interlocks, and assembly/inspection aids.

• Decision-making for manual versus automated manufacturing operations.

• Estimation of full-time equivalent (FTE) requirements and station-level utility requirements.

3. Material Flow & Replenishment Engineering

• Design of line-side material replenishment strategies.

• Experience with overhead conveying, manual material movement, forklift trucks (FLT), AGVs, and AMRs.

• Calculation of line-side replenishment frequency and material supply requirements.

• Material flow planning, inventory tracking, and production logistics.

• Ability to optimize material movement, reduce waste, and improve manufacturing throughput.

4. Modeling, Simulation & Line Optimization

• Experience providing engineering inputs to modeling and simulation specialists.

• Understanding of:

  • Material Flow Simulation

  • Discrete Event Simulation (DES)

  • Station-Level Process Simulation

  • Ergonomics (Ergo) Simulation

• Ability to define what-if scenarios, review simulation results, and recommend design changes.

• Experience redesigning and improving production lines based on simulation outcomes.

• Knowledge of CAD design platforms and manufacturing simulation tools.

5. Automation, Controls & Systems Integration

• Experience providing engineering inputs for robotics, AGVs, AMRs, machine vision, and automated inspection systems.

• Understanding of controls engineering, sensors, sequencing, and error-proofing interlocks.

• Ability to define requirements for data acquisition, inventory tracking, and plant IT integration.

• Familiarity with Quality Management System (QMS) integration and manufacturing systems.

• Experience coordinating automation requirements with controls engineers, system integrators, and equipment suppliers.

6. Equipment Engineering, Safety & Certification

• Experience working with line builders, equipment suppliers, technology OEMs, and manufacturing equipment vendors.

• Ability to develop equipment specifications, tooling requirements, and technical work packages.

• Understanding of Health, Safety, and Environment (HSE) requirements and station-level utility needs, including WAGES (Water, Air, Gas, Electricity, and Steam).

• Knowledge of equipment certification requirements across different regions.

• Experience coordinating equipment certification with third-party certification agencies.

Roles & Responsibilities

• Analyze customer requirements and translate manufacturing needs into line engineering and design specifications.

• Define work packages, engineering scope, deliverables, project estimates, and schedules.

• Lead converting line design, process planning, line balancing, workstation design, and layout development.

• Determine station count, throughput, cycle time, FTE requirements, and material replenishment frequency.

• Develop line-side storage, trolley designs, material presentation methods, conveying concepts, and part-loading solutions.

• Specify tools, assembly aids, inspection aids, equipment, and error-proofing mechanisms for individual stations.

• Collaborate with CAD design engineers and provide detailed engineering inputs for line layouts and equipment design.

• Work with simulation teams to evaluate material flow, discrete-event, process, and ergonomics simulation results.

• Recommend line redesigns and process improvements based on simulation outcomes and manufacturing performance.

• Coordinate automation requirements involving robotics, AGVs, AMRs, vision systems, controls, and sensors.

• Provide inputs for plant IT, sequencing, data acquisition, inventory tracking, and QMS integration.

• Collaborate with line builders, OEMs, equipment suppliers, plant leadership, and customer engineering teams.

• Lead customer interactions, technical reviews, design reviews, and project status meetings.

• Coordinate with onsite customers and offshore engineering teams to ensure timely delivery.

• Support equipment installation, commissioning, validation, and final customer handover.

• Provide post-deployment technical support and resolve line design or operational issues.

• Identify additional opportunities for manufacturing optimization and automation across plants and customer sites.

Required Qualifications

• 8–20 years of experience in manufacturing systems engineering, production line design, industrial engineering, or manufacturing engineering.

• Strong experience in converting line design and web-processing manufacturing environments.

• Proven capability in line layout, workstation design, Bill of Process, line balancing, and throughput planning.

• Experience with material handling, line-side replenishment, conveying systems, and manufacturing equipment specifications.

• Exposure to CAD and manufacturing simulation platforms.

• Experience working with simulation teams and translating results into engineering improvements.

• Understanding of automation integration, controls, plant IT, and quality systems.

• Experience coordinating with equipment OEMs, line builders, suppliers, and third-party certification agencies.

• Strong customer-facing communication, technical leadership, problem-solving, and project coordination skills.

Preferred Qualifications

• Exposure to AI, Generative AI, or AI-enabled manufacturing optimization.

• Experience with advanced automation technologies, robotics, AGVs, AMRs, and machine vision.

• Knowledge of lean manufacturing, Value Stream Mapping (VSM), continuous improvement, and waste reduction.

• Experience with manufacturing quality systems, inventory tracking, and enterprise system integration.

• Experience leading installation, commissioning, equipment certification, and customer handover activities.

• Familiarity with global manufacturing standards and regional equipment certification requirements.

Core Dice Search Keywords

Converting Line Design, Converting Line Engineering, Manufacturing Systems Engineering, Manufacturing Systems Engineer, Systems Engineering Lead, Manufacturing Engineering Lead, Industrial Engineering, Production Line Design, Line Layout Design, Bill of Process, BOP, Converting Processes, Web Handling, Unwinding, Splicing, Threading, Web Tension Control, Slitting, Coating, Curing, Cutting, Packaging Automation, Workstation Design, Line Balancing, Throughput Optimization, Cycle Time, Material Flow, Line-Side Storage, Material Replenishment, Material Handling Equipment, MHE, AGV, AMR, Conveyor Design, CAD, Manufacturing Simulation, Material Flow Simulation, Discrete Event Simulation, DES, Ergonomics Simulation, Ergo Simulation, Value Stream Mapping, Lean Manufacturing, Error Proofing, Poka-Yoke, PLC, Controls Engineering, Machine Vision, Robotics Integration, Plant IT Integration, QMS Integration, Equipment Specification, OEM Management, Equipment Certification, HSE, Installation and Commissioning, Manufacturing Optimization.