Materials and Logistics Process Engineer

Position Summary

Drive the design and improvement of sustaining warehouse, material flow, inventory management, transportation, and logistics processes to support operational excellence. This role focuses on increasing productivity, reducing costs, improving inventory accuracy, optimizing warehouse layouts and material presentation to production, and ensuring on-time delivery performance through continuous improvement initiatives and data-driven decision making.

The position works closely with Operations, Supply Chain, Manufacturing, Quality, Purchasing, and Logistics teams to identify process improvement opportunities and implement scalable solutions that enhance efficiency, safety, and customer satisfaction.

Key Responsibilities

Process Improvement & Optimization

• Analyze existing warehouse and logistics processes to identify trends, bottlenecks, inefficiencies, and improvement opportunities.
• Lead continuous improvement projects utilizing Lean Manufacturing tools such as Six Sigma, Kaizen, value stream mapping methodologies, Spaghetti Diagrams, Root Cause Analysis, 5 Why, Pareto Analysis, etc…
• Drive productivity improvements through workflow optimization and waste elimination.
• Establish key performance indicators (KPIs) to measure warehouse and logistics performance.
• Perform cost-benefit analyses and support business case development for capital and operational improvements.
• Utilize statistical tools and process data to drive decision-making and continuous improvement.

Warehouse Operations Engineering

• Evaluate inventory storage methods to maximize space utilization and material accessibility.
• Support implementation and optimization of Warehouse Management Systems (WMS).
• Establish standard work and operating procedures for warehouse and logistics activities.

Material Flow & Material Pull Handling (MPH)

• Analyze and improve material flow from receiving through storage, picking, replenishment, production consumption, and shipping.
• Lead the implementation and continuous improvement of warehouse layouts, Material Pull Handling (MPH) processes, and internal logistics flows according to Lean principles.
• Define replenishment strategies and material presentation methods at point-of-use.
• Develop and maintain material call systems, Kanban cards, withdrawal cards, and replenishment triggers.
• Ensure continuous material availability while minimizing inventory and handling activities.
• Support implementation and optimization of Water Spider methodologies and material delivery routes.

Packaging, Logistics, & Transportation

• Support the optimization of inbound and outbound transportation processes to improve delivery performance and reduce costs.
• Collaborate with carriers, suppliers, and third-party logistics providers (3PLs) to improve service levels.
• Develop transportation scheduling and freight optimization strategies.
• Monitor logistics performance metrics and identify corrective actions when targets are not met.
• Collect and analyze data related to packaging requirements and material handling.
• Support packaging optimization projects to improve warehouse efficiency, transportation effectiveness, and material protection.
• Support the design and standardize packaging solutions aligned with operational needs and Lean principles.

Project Management

• Lead warehouse and logistics improvement projects from concept through implementation.
• Coordinate cross-functional teams to ensure successful project execution.
• Manage project timelines, deliverables, risks, and budgets.
• Support equipment selection, facility expansions, automation projects, and technology implementations.

Safety & Compliance

• Ensure warehouse and logistics processes comply with company safety policies, environmental, and regulatory requirements.
• Participate in safety assessments, ergonomics, and health evaluations.
• Support inventory control, quality standards, and audit compliance requirements.
• Promote a culture of safety, continuous improvement, and operational excellence.

Required Qualifications

• Bachelor's degree in Industrial, Manufacturing, or Mechanical Engineering,
• 5-10 years of experience in warehouse operations, logistics, and process engineering.
• Experience with use of 3D CAD modeling software such as SolidWorks
• Experience with Lean Manufacturing, Kaizen Methodology, 5S, Continuous Improvement, and process optimization techniques.
• Strong analytical and problem-solving skills.
• Proficiency with Microsoft Excel, ERP systems, and Warehouse Management Systems (WMS).
• Strong communication and cross-functional collaboration skills.

Preferred Qualifications

• Lean Six Sigma Green Belt or Black Belt certification.
• Knowledge of warehouse automation technologies and material handling systems.
• Experience in manufacturing, distribution, or high-volume fulfillment environments.
• Familiarity with transportation management systems (TMS) and inventory optimization tools.
• Project management experience with multiple concurrent initiatives.

Travel: Up to 10-20% as required for supplier, warehouse, or logistics network support.