Material Flow Automation Engineer

Rush Group Limited LLC; Louisville (KY); Hybrid; USD 90,000 - 130,000; Full time

Benefits offered by this job

Paid time off

Medical, dental, and vision coverage

401(k) plan

Job summary

Emotiv is seeking a strategic, hands-on Material Flow Automation Engineer to design, implement, and optimize automated material handling across manufacturing and warehousing. You will leverage AMRs, AGVs, conveyors, and digital twins to create scalable, data-driven systems that improve safety, throughput, and efficiency.

The role spans MSS and VAA spaces, reports to the Director of AME & Automation, and is based in a hybrid model with locations in Kansas City, Louisville, or Detroit.

Qualifications

• Hands-on experience with material flow automation in manufacturing or distribution.
• Experience evaluating and integrating AMRs, AGVs, conveyors, storage systems, and fleet-management.
• Familiarity with WMS, ERP, MES/FMS, inventory, traceability, and digital replenishment.

Responsibilities

• Develop automation strategies for receiving, storage, sequencing, line-side delivery, and finished goods.
• Analyze material flow, forklift activity, routes, and replenishment to improve safety and throughput.
• Lead projects from concept through commissioning and ramp-up, including testing and handoff.

Skills

AMRs

AGVs

Conveyors

Automated storage

Robotics

Fleet management systems

Digital twin

Discrete-event simulation

Lean manufacturing

Industrial controls

WMS

ERP

MES/FMS

Microsoft Office

AutoCAD

Education

Bachelor's degree in Industrial, Manufacturing, Mechanical, Mechatronics, Supply Chain, Logistics Engineering, or related field

Tools

AutoCAD

Microsoft Office

Job description

At Emotiv, we don't just move materials. We accelerate possibility. We are reimagining mobility with advanced warehousing and sequencing solutions trusted by leading automotive OEMs. We are a team of doers, thinkers, and builders who believe operational excellence is achieved through empowered people and a constant drive to improve.

If you're looking for a company where you can be seen, grow, and help shape the future of supply chain innovation, we'd love to meet you.

The Role

We are seeking a strategic, hands-on, and innovative Material Flow Automation Engineer to lead the design, standardization, implementation, and optimization of automated material handling and material flow systems across our manufacturing and warehousing operations, including Manufacturing Support Services (MSS) and Value-Added Assembly (VAA) spaces. This role will transform traditional material handling into safe, scalable, data-driven systems using AMRs, autonomous forklift trucks (AFTs), conveyors, lift-assist equipment, smart storage, fleet management tools, simulation software, digital twin models, and integrated controls.

The ideal candidate is a hands-on, analytical problem solver with experience in high-volume manufacturing, material handling automation, logistics, and continuous improvement. They are passionate about leveraging technology to enhance operational performance, streamline material movement, and support scalable growth

This is a hybrid position based in Kansas City, Louisville, or Detroit. The role reports to the Director of AME & Automation and is part of the Engineering team.

What You'll Do

• Develop automation strategies for receiving, storage, kitting, sequencing, line-side delivery, finished goods, dunnage, and empty-container return.
• Analyze material flow, inventory movement, forklift activity, routes, and replenishment processes to improve safety, quality, productivity, and throughput.
• Develop and maintain material layouts, storage concepts, line-side presentation standards, traffic paths, and end-to-end material flow designs for MSS and VAA operations, balancing safety, space utilization, labor, inventory, throughput, and launch requirements.
• Partner with plant leadership and cross-functional teams to define current-state constraints, validate root causes, and implement practical solutions for material flow, congestion, line-side delivery, storage, quality, productivity, and capacity challenges.
• Specify and integrate AMRs, AGVs, conveyors, automated storage, lift equipment, scanners, sensors, controls, and fleet-management systems.
• Lead the selection, supplier assessment, proof-of-concept testing, factory and site acceptance testing, validation, and deployment of AMRs, AFTs, tuggers, autonomous forklifts, and other MHE solutions.
• Define equipment and system acceptance criteria covering payload and load stability, acceleration/deceleration, turning radius and aisle requirements, docking accuracy, stopping distance, dynamic obstacle avoidance, charging, availability, fleet sizing, traffic management, and production-rate capability.
• Lead automation projects from concept and sourcing through installation, commissioning, validation, training, handoff, and ramp-up.
• Design material-delivery standards covering storage, line-side presentation, traffic flow, docking, charging, payload transfer, and facility interfaces.
• Use layouts, time studies, labor analysis, simulation, and digital twins to validate concepts, size equipment, and reduce implementation risk.
• Develop, validate, and maintain digital twin and discrete-event simulation models to evaluate capacity, throughput, route congestion, storage utilization, labor, equipment utilization, fleet mix, delivery cycles, bottlenecks, and future-state scenarios before physical implementation.
• Translate operational data and simulation outputs into scenario comparisons, sensitivity analyses, capital requests, total-cost-of-ownership evaluations, ROI/payback cases, and clear recommendations for plant and executive decisions.
• Integrate material automation with WMS, ERP, MES/FMS, inventory transactions, production signals, traceability, and dispatch systems.
• Support Industry 4.0 integration by defining data, controls, software, and interface requirements across WMS, ERP, MES/FMS, PLCs, fleet-management systems, sensors, RTLS/IoT devices, APIs, and production signals, with attention to traceability, cybersecurity, data ownership, and maintainability.
• Support quoting, launches, expansions, and engineering changes by defining equipment, labor, space, capital, assumptions, milestones, and risks.
• Develop technical requirements, scopes of work, compliance matrices, responsibility matrices, test plans, and RFQ/RFI packages for turnkey/end-to-end integrators, integration partners, and equipment OEMs; lead technical bid reviews, supplier clarifications, assumption/risk closure, and sourcing recommendations.
• Evaluate RFQ responses for technical compliance, functional safety, VDA 5050 or comparable mixed-fleet interoperability, controls architecture, fleet and charging concepts, software licensing, lifecycle support, spare parts, service coverage, lead time, implementation risk, scalability, warranty, recurring fees, and total cost of ownership.
• Coordinate end-to-end delivery from concept and supplier selection through design, controls and equipment interfaces, installation, commissioning, training, ramp-up, handoff, and post-launch performance verification, while clearly defining owner-furnished equipment and supplier responsibilities.
• Establish standards for fleet management, mapping, traffic control, charging, safety, machine interfaces, and interoperability.
• Reduce forklift use, unnecessary movement, inventory handling, ergonomic risk, shortages, downtime, and floor-space requirements.
• Maintain layouts, process flows, specifications, automation standards, launch checklists, and lessons learned.

Who You Are

• Bachelor's degree in Industrial, Manufacturing, Mechanical, Mechatronics, Supply Chain, Logistics Engineering, or related field preferred. Equivalent combination of education, military training, certifications, and relevant industry experience will be considered.
• 3+ years of experience in manufacturing, warehousing, logistics, material handling, automation, or industrial engineering.
• Experience designing, implementing, and optimizing material flow and automation systems in manufacturing or distribution environments.
• Hands-on experience with automated material handling technologies, including AMRs, AGVs, conveyors, automated storage, robotics, controls, and fleet-management systems.
• Knowledge of automation safety, machine integration, risk assessment, and industrial controls.
• Familiarity with WMS, ERP, MES/FMS, inventory management, traceability, and digital replenishment systems.
• Ability to develop layouts, process flows, labor models, equipment specifications, capital requests, and project plans.
• Experience developing, validating, or applying digital twin and discrete-event simulation models to evaluate capacity, throughput, resource utilization, congestion, fleet sizing, material flow performance, and future-state scenarios.
• Working literacy in Digital Twin, simulation, and Industry 4.0 concepts, including connected assets, IoT/RTLS, data pipelines, production-system integration, KPI design, scenario modeling, and data-driven decision support.
• Experience using operational data and simulation results for sensitivity analysis, capacity planning, equipment sizing, total-cost-of-ownership analysis, ROI/payback development, and capital justification.
• Working knowledge of Lean manufacturing, continuous improvement, ergonomics, and standard work principles.
• Proficiency with Microsoft Office, AutoCAD (or similar), project management tools, and industrial simulation platforms.
• Strong analytical, project management, supplier management, problem-solving, communication, and cross-functional leadership skills, with the ability to work directly with plant teams and translate operational challenges into practical, scalable solutions.
• Experience supporting RFQ/RFI development and technical supplier evaluation for material handling or automation systems; familiarity with compliance matrices, acceptance criteria, FAT/SAT, functional safety, equipment interfaces, software licensing, service models, and lifecycle-cost comparisons.
• Knowledge of mixed-fleet orchestration and interoperability principles, including VDA 5050 or comparable open-interface approaches, is preferred.

Health, Safety, Physical & Travel Requirements

• Ability to sit, stand, and move freely within office and plant environments; capable of performing standard computer-based work.
• Approximately 50% of travel required
• Valid driver’s license required

Life at Emotiv

We believe great work happens when people feel valued, supported, and connected. At Emotiv, you will find a culture built on collaboration, learning, and celebrating wins of all sizes. We offer competitive pay, comprehensive benefits, and opportunities to grow your career alongside industry leaders who are shaping the future of sustainable mobility.

Our benefits include paid time off, medical, dental, and vision coverage, and a 401(k) plan for eligible employees.

Equal Opportunity Employer/Protected Veterans/Individuals with Disabilities
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