Material Flow Engineer (Factory Warehouse Design and Material Flow)

The role

The Material Flow Engineer owns the full lifecycle of material flow and process equipment from concept to operational handoff. This role involves designing automated material handling systems, optimizing warehouse layouts, and managing PFEP strategies.

What you will do

• Own the full lifecycle of material flow and process equipment from concept through operational handoff.
• Design and implement automated and semi-automated material handling systems.
• Develop system architectures, throughput models, capacity analyses, and business cases.
• Design and optimize warehouse layouts, lineside storage, and material flow pathways.
• Manage PFEP strategies to ensure efficient inventory movement and production support.
• Evaluate, select, and support procurement of material handling equipment and automation.
• Build and execute discrete event simulation models to analyze performance.
• Collaborate with Manufacturing, Operations, Supply Chain, and other engineering teams.
• Lead project execution including vendor management, RFQ development, and budgeting.
• Analyze operational metrics to drive continuous improvement initiatives.

Required qualifications

• Bachelor’s degree in Industrial Engineering, Mechanical Engineering, or a related technical field.
• 5+ years of experience in manufacturing, automation, material handling, warehouse design, or logistics engineering environments.
• Proven experience designing and implementing material flow systems including AGVs, AMRs, AGCs, conveyors, robotics, VRCs, and ASRS technologies.
• Strong expertise in end-to-end warehouse design, material flow analysis, and factory logistics optimization.
• Experience with buffer analysis, lineside inventory planning, finished goods storage, and aisle sizing methodologies.
• Hands-on experience developing and managing PFEP (Plan for Every Part) strategies.
• Proficiency with AutoCAD, SolidWorks, FlexSim, or similar simulation and factory modeling tools.
• Experience evaluating, selecting, procuring, and commissioning material handling equipment and automation solutions.
• Strong knowledge of controls integration including PLC, MES, and WMS systems.
• Knowledge of Lean Manufacturing, Just-in-Time (JIT), continuous improvement principles, and industrial safety standards.
• Proven project management experience including vendor coordination, budgeting, scheduling, and implementation oversight.
• Ability to analyze manufacturing KPIs and convert data into actionable operational improvements.

Nice to have

• Experience with Python, SQL, Power BI, Tableau, or similar analytics tools

Benefits

• mentorship
• career growth opportunities
• comprehensive benefits

Before you apply

• All candidates selected for employment will be required to successfully complete a pre-employment drug screening as a condition of hire.

About the company

ALTEN Technology USA is an engineering company with 3,000+ experts across North America. They partner with leading companies in aerospace, medical devices, robotics, automotive, and more.