Layout Engineer (Industrial Engineering / Factory & Site Design)

Job Details
Sr LayOut Engineer
Long Term Contract
Pittsburg, PA

The Layout Engineer will be responsible for end-to-end site and factory layout management, including building-level and campus-level planning. This role focuses on designing, optimizing, and scaling manufacturing facilities by integrating production systems, material flow, warehouse operations, and site infrastructure into a cohesive and efficient layout. The ideal candidate will combine industrial engineering expertise, data-driven analysis, and cross-functional leadership to support large-scale manufacturing growth.

Key Responsibilities
•    Develop and own integrated IE models that connect capacity, labor, material flow, PFEP, and cost (COGS) to support factory planning and operations
•    Build and maintain capacity models (target vs. forecast vs. gated capacity), incorporating cycle time, OEE, yield losses, and bottleneck analysis
•    Develop labor models to optimize headcount, utilization, and labor cost (LOH) across production systems
•    Create and evaluate business cases for capital investments, including ROI, IRR, NPV, and cost benefit analysis
•    Lead COGS modeling, including labor, overhead, scrap, and process-driven cost components
•    Develop and track scrap and yield models, quantifying cost impact and identifying improvement opportunities
•    Design and maintain OEE models (availability, performance, quality) to drive operational efficiency and continuous improvement
•    Perform buffer and WIP analysis to optimize inline and interline storage, reduce bottlenecks, and stabilize production flow
•    Develop process flow diagrams (PFDs) and value stream maps to represent manufacturing systems and identify inefficiencies
•    Integrate PFEP (Plan for Every Part) data into models to optimize material flow, storage, and line-side delivery strategies
•    Support factory layout, site planning, and material flow decisions through data-driven insights and modeling
•    Perform scenario analysis and sensitivity studies to evaluate production strategies and capacity expansion plans
•    Utilize and/or develop factory simulation models (e.g., FlexSim, AnyLogic, Simio) to analyze throughput, bottlenecks, and system performance
•    Support factory ramp-up, installation, and operational readiness through model validation and
Performance tracking 
•    Collaborate with cross-functional teams (Manufacturing, Operations, Supply Chain, Finance, Engineering) to align models with real-world constraints and business needs Translate complex analytical outputs into clear, executive-level insights and recommendations
•    Collaborate with MES and Controls teams to integrate shop-floor data with IE models, ensuring accurate OEE measurement and enabling real-time, scalable dashboards for operational visibility and executive decision-making

AI & Data Systems
•    Introduce and implement AI-driven tools and platforms to enhance industrial engineering analytics and decision-making
•    Design and manage scalable data models and data architecture for IE, capacity, labor, PFEP, and cost analytics
•    Develop standardized systems, frameworks, and governance for data modeling, analytics, and reporting
•    Automate data collection, validation, and reporting pipelines using AI and advanced analytics tools
•    Enable predictive analytics and intelligent decision-making for capacity, throughput, and cost optimization
•    Establish best practices for data quality, model standardization, and system integration across the organization

Basic Qualifications
•    Bachelor’s degree in Industrial Engineering, Mechanical Engineering, Operations Research, or a related field
•    7 years of experience in industrial engineering analytics, manufacturing modeling, or operations analysis
•    Strong understanding of manufacturing systems, capacity planning, and industrial engineering principles

Key Skills & Competencies
•    Strong analytical and data-driven decision-making skills
•    Ability to manage complex, cross-functional projects across site and factory levels
•    Excellent communication skills with the ability to influence stakeholders from shop floor to executive leadership
•    Systems-thinking mindset with attention to detail
•    Proven ability to manage multiple priorities in a fast-paced, high-growth environment

Preferred Qualifications
•    Experience building end-to-end IE models integrating capacity, labor, cost, PFEP, and material flow
•    Proficiency in capacity modeling, OEE analysis, cycle time studies, and line balancing
•    Hands-on experience with PFEP, material flow optimization, and warehouse integration
•    Experience with factory simulation tools (e.g., FlexSim, AnyLogic, Simio)
•    Strong experience in business case development (ROI, IRR, NPV)
•    Knowledge of COGS modeling, cost structures, and financial impact analysis
•    Experience with data analysis tools (Excel advanced modeling, Python, SQL, Power
•    BI/Tableau, or similar)
•    Familiarity with AI/ML applications in manufacturing analytics (preferred)
•    Familiarity with lean manufacturing and continuous improvement methodologies

Key Skills & Competencies
•    Strong analytical and problem-solving skills with a data-driven mindset
•    Ability to build scalable models and analytics systems that support both tactical and strategic decisions
•    Strong communication skills to translate complex data into actionable insights
•    Ability to work across cross-functional teams and influence decision-making
•    Attention to detail with a systems-level understanding of manufacturing operations
•    Ability to manage multiple projects and priorities in a fast-paced environment

Preferred Qualifications:
•    Bachelor’s degree in Industrial Engineering, Mechanical Engineering, Manufacturing Engineering, or related field
•    7 years of experience in site/factory layout planning, industrial engineering, or manufacturing systems
•    Experience in large-scale manufacturing environments (e.g., automotive, battery, energy, or heavy industry)
•    Strong understanding of site planning, material flow, and facility design principles
•    Experience in greenfield site development and large-scale factory ramp-up
•    Proven experience in site master planning, including yard design, dock strategy, and infrastructure planning
•    Hands-on experience with PFEP, warehouse design, and material handling systems (AGVs, AMRs, conveyors)
•    Proficiency in layout tools such as AutoCAD, Revit, or similar 2D/3D design software
•    Experience with simulation tools (e.g., FlexSim) for factory and logistics modeling
•    Strong knowledge of Capacity Model and Labor industrial engineering methodologies (OEE, line balancing, takt time, cycle time analysis)
•     Experience working with construction and facilities teams on site execution and infrastructure integration
•    Familiarity with safety, environmental, and regulatory considerations in site design