Material Flow Engineer

Location: Pittsburgh, PA (Onsite)

What You'll Do: 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, AGC, 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 AMR/AGV/AGC technologies, 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, FAT/SAT, 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 AGV/AMR 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, AGC, VRC, conveyors, robotics, and ASRS design, integration, and commissioning. Strong proficiency in AutoCAD, SolidWorks, and factory simulation/flow 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 (PLC/MES/WMS) and industrial safety standards (ANSI/ISO/IEC). 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.