Layout Design Engineer

KK Software Associates; Pittsburgh (Allegheny County); On-site; USD 120,000 - 180,000; Full time

Job summary

KK Software Associates is seeking a senior Layout Engineer to drive end-to-end site and factory layout management, integrating production systems, material flow, and facilities into a cohesive plan. You will lead cross-functional teams to design scalable layouts supporting large-scale manufacturing growth.

The role requires a strong industrial engineering background, data-driven analysis, and proven leadership to optimize space, flow, and cost across complex sites.

Qualifications

• Bachelor’s degree in Industrial, Mechanical, Manufacturing, or related engineering field.
• 7+ years in site/factory layout planning or related industrial engineering.
• Experience in large-scale manufacturing environments (auto, battery, energy, heavy industry).
• Strong understanding of site planning, material flow, and facility design principles.

Responsibilities

• Lead factory layout design across manufacturing lines, storage areas, and flow.
• Develop long-term site master plans to support capacity expansion.
• Define layout governance, standards, and change management processes.
• Create and maintain 2D/3D layouts aligned with POR and business needs.
• Design end-to-end material flow from inbound to outbound finished goods.
• Own site layout including building placement, utilities, and external logistics.
• Collaborate with cross-functional teams to align on layout requirements.
• Perform data-driven analysis to optimize space, flow, labor productivity and cost.
• Track layout metrics such as flow distance, aisle utilization, throughput.
• Support capacity planning and modeling using OEE, takt time, cycle time.
• Drive densification initiatives to reduce non-value-added movement.
• Translate complex data into executive-level insights for strategic decisions.

Education

Engineering degree (IE / Mechanical / Manufacturing)

Tools

AutoCAD

Revit

FlexSim

Job description

Type : Long term Contract

Role Overview:

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.

Basic 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

Key Responsibilities:

• Lead factory layout design across manufacturing lines, warehouse/storage areas, material flow, people flow, and ancillary/support spaces
• Develop long-term site master plans to support phased capacity expansion and future scalability
• Define and implement layout governance and standards, including change management, visual factory standards, drafting standards, and layout processes
• Create and maintain block layouts and detailed 2D/3D layouts aligned with Plan of Record (POR) and business requirements
• Design and optimize end-to-end material flow, including inbound, internal logistics (WIP), and outbound finished goods flow
• Own and manage overall site layout, including building placement, external logistics flow (truck movement, dock doors, yards), utilities, and infrastructure planning
• Optimize dock utilization, yard flow, and transportation interfaces to improve logistics efficiency at the site level
• Collaborate with cross-functional teams (Manufacturing, Operations, Supply Chain, Facilities, Construction, EHS) to align on layout requirements and ensure seamless execution
• Perform data-driven analysis to optimize space utilization, flow efficiency, labor productivity, and cost
• Develop and integrate PFEP (Plan for Every Part) into layout decisions, including storage strategy, packaging, and line-side delivery
• Define and track layout performance metrics, including flow distance, aisle utilization, space density, throughput, and bottlenecks
• Support capacity planning and modeling using OEE, cycle time analysis, and throughput simulations
• Drive factory densification initiatives by eliminating non-value-added movement and improving layout efficiency
• Support installation, commissioning, and layout validation during site construction and production ramp-up
• Translate complex layout and operational data into clear, executive-level insights to support strategic decisions

Preferred Qualifications:

• 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
• 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