Expert Partner - Factory Masterplanning

OperationsCatalyst; United States; Remote; USD 225,000 - 300,000; Full time

Job summary

OperationsCatalyst is searching for an Expert - Factory Masterplanning to lead strategic brownfield expansion initiatives. This position merges technical expertise with business strategy, guiding manufacturers in making data-driven decisions for facility expansions and optimizations. Candidates should possess substantial experience in facility planning and brownfield operations.

Benefits

Equity participation in a growing consulting firm

Fully remote working environment

Qualifications

• 12+ years in facility planning and factory design.
• Proven track record of managing projects from $10M to $500M+.
• Excellent client relationship management and executive presentation skills.

Responsibilities

• Conduct comprehensive existing facility assessments.
• Develop 5-10 year brownfield expansion master plans.
• Design optimized expansion layouts that integrate with existing systems.

Skills

Facility planning

Capacity optimization

Brownfield expansion

Client relationship management

Financial modeling

Lean manufacturing principles

Education

Bachelor's Degree in Engineering or related field

Advanced proficiency in software like AutoCAD

Tools

Microstation

Revit

AutoCAD

Plant Simulation

FlexSim

Job description

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OperationsCatalyst seeks an Expert - Factory Masterplanning to lead strategic brownfield expansion and optimization initiatives for manufacturing clients. This role combines technical rigor with business strategy to ensure manufacturers make data-driven decisions about existing facility expansions, equipment upgrades, and capacity optimization within operational constraints. The position requires deep expertise in brownfield facility planning, existing system integration, and strategic expansion development to guide clients through complex growth decisions while maintaining production continuity.

KEY RESPONSIBILITIES

Strategic Planning & Analysis

• Conduct comprehensive existing facility assessments using capacity planning methodologies, value stream analysis, and DMAIC frameworks
• Develop 5-10 year brownfield expansion master plans that optimize existing assets while accommodating growth objectives and sustainability targets
• Lead feasibility studies for brownfield expansions, facility retrofits, and existing system optimization across operational manufacturing sites
• Create phased expansion roadmaps that balance production continuity with capacity additions and infrastructure upgrades
• Establish current-state capacity utilization baselines and identify expansion opportunities within existing facility constraints
• Evaluate existing energy-intensive manufacturing processes and infrastructure capacity for expansion without production disruption

Technical Design & Implementation

• Design optimized expansion layouts that integrate with existing material flow, utilities, and continuous production systems
• Develop modular brownfield expansion concepts that enable phased growth while maintaining operational continuity
• Create digital twins and simulation models of existing facilities using Plant Simulation, FlexSim, or equivalent platforms for expansion planning
• Coordinate equipment integration and installation planning within active production environments
• Plan equipment upgrades and capacity additions for energy-intensive operations while minimizing production downtime
• Translate expansion requirements into construction-ready specifications that work within existing structural and infrastructure constraints

Client Engagement & Value Delivery

• Lead executive planning workshops and cross-functional stakeholder alignment sessions
• Establish KPIs and measurement frameworks to track expansion ROI and operational improvements
• Manage client relationships through complex, multi-year facility development projects
• Present strategic recommendations to C-level executives with clear financial justification
• Facilitate decision-making processes that balance technical requirements with business constraints
• Establish standardized brownfield expansion planning templates, tools, and assessment frameworks for energy-intensive manufacturing operations
• Create repeatable evaluation criteria for existing facility optimization, equipment integration, and expansion feasibility analysis
• Develop risk assessment methodologies for brownfield expansion decisions including production continuity risks and existing system constraints
• Build scalable processes for brownfield masterplanning that incorporate operational constraints and phased implementation requirements
• Design expansion assessment frameworks that integrate existing asset utilization with capacity growth and sustainability goals

QUALIFICATIONS

Required Experience

• 12+ years in facility planning, factory design, or manufacturing engineering with at least 5 years in brownfield expansion and retrofit projects
• Proven track record managing brownfield expansion investments from $10M to $500M+ across energy-intensive manufacturing, metals processing, or continuous production industries
• Experience leading facility expansions, equipment integration, and capacity optimization within active manufacturing environments
• Demonstrated success in brownfield capacity planning, existing system optimization, and expansion project management for high-volume operations
• Background in energy-intensive manufacturing expansions, including continuous casting, metal processing, or similar brownfield operations, preferred
• Ability to translate business strategy into facility requirements and implementation roadmaps
• Strong financial modeling capabilities for capital investment analysis and ROI justification
• Experience managing cross-functional teams, including engineering, operations, and project management professionals
• Excellent client relationship management and executive presentation skills

Technical Expertise

Required:

• Advanced proficiency in facility design software (Microstation, Revit, AutoCAD, Plant Simulation, FlexSim)
• Deep understanding of lean manufacturing principles, value stream mapping, and operational excellence methodologies
• Understanding of existing system integration, utility capacity assessments, production continuity planning, and infrastructure upgrade requirements
• Expertise in energy management systems, carbon reduction initiatives, and sustainability retrofits for existing operations
• Experience with expansion planning for continuous production processes, existing equipment integration, and minimal-downtime installations

Preferred:

• Experience with BIM modeling, digital twin development, and VR/AR facility visualization for existing facility integration

COMPENSATION & STRUCTURE

• Equity participation in a high-growth consulting firm
• Fully remote working environment with travel requirements (10-20%)
• Must be located in the US Eastern Time Zone for client collaboration and team coordination

ABOUT OPERATIONSCATALYST

OperationsCatalyst delivers transformation solutions that turn fractured systems into streamlined, measurable operations. We specialize in helping manufacturers, automation OEMs, and integrators navigate digital transformation, operational excellence, and strategic growth initiatives. Our approach combines strategic vision with tactical implementation, ensuring clients achieve measurable results across sales, delivery, and operational infrastructure.

We work with industry leaders who require technical rigor combined with business acumen—exactly the expertise needed to make critical facility investment decisions that drive long-term competitive advantage.

Apply now to lead facility masterplanning initiatives that shape the future of manufacturing excellence.

Seniority level

• Seniority level

  Mid-Senior level

Employment type

• Employment type

  Full-time

Job function

• Job function

  General Business, Management, and Business Development

• Industries

  Business Consulting and Services

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