Material Flow Engineer

Life in Pittsburgh; Pittsburgh (Allegheny County); On-site; USD 110,000 - 160,000; Full time

Job summary

Tech Mahindra in Pittsburgh, PA is seeking a Material Flow Engineer to own the full lifecycle of material flow and process equipment. You will design and deploy automated material flow systems (AGV/AMR/VRC/conveyors/robotics) and work with MES/WMS/PLC integrations to optimize production lines.

You will lead cross-functional teams, model capacity, and drive continuous improvement through data-driven insights and DES simulations to enhance throughput and safety.

Qualifications

• Bachelor’s or Master’s degree in Industrial or Mechanical Engineering (or a related technical field).
• 5+ years of experience in manufacturing, automation, or material handling engineering within high-volume or logistics environments.
• Proven expertise in AGV, AMR, AVRC, conveyors, robotics, and ASRS design, integration, and commissioning.

Responsibilities

• Own the full lifecycle of material flow and process equipment—from concept to handover.
• Design and deploy automated material flow systems (AGV, AMR, VRC, conveyors, robotics).
• Specify system requirements and ensure safety and ergonomic compliance.
• Develop capacity and throughput models and balance OPEX/CAPEX.
• Lead cross-functional teams to integrate automation with MES/WMS/PLC systems.
• Lead end-to-end program management including vendor RFQs, FAT/SAT, and milestones.
• Build DES models (e.g., FlexSim) to evaluate capacity and resource use.
• Provide data-driven insights for strategic and operational decisions.
• Define fleet management and path optimization for AGV/AMR systems.

Skills

Leadership

Project management

Analytical

Communication

Lean Manufacturing

Continuous improvement

Education

Bachelor’s or Master’s in Industrial or Mechanical Engineering

Tools

AutoCAD

SolidWorks

FlexSim

PLCs / MES / WMS

AMR/AGV

ASRS

Conveyors

Job description

About Us:

At Tech Mahindra (), we live the philosophy of connected world and connected experiences. We thrive on change that is powered by the intelligent symphony of technology and humans designing meaningful and sustainable experiences. Consumer ‘experiences’ are driving and disrupting industries like never before. Businesses must build seamless yet simple enterprises that collaborate, synergize, and drive the change. Change that connects us all and empowers us to deliver experiences that span across the digital, the physical, the convergent, and everything in between. That’s when truly connected experiences manifest.

Extraordinary is when experiences come together – a continuous convergence of digital technologies, touchpoints, and most importantly people. It’s time to reimagine, reinvent, and revolutionize business models & operations as well as to transform enterprises into living, breathing, and connected businesses. We are the Digital Change makers who strive to change the way the world, communities, businesses, and humans interact digitally. We are harnessing the power of change, brought in by technologies, that makes it the most exciting time to be alive in the human history. Our universe, as we build it, disrupt it, and redesign it, is powering the digital change.

Tech Mahindra represents the connected world, offering innovative and customer-centric information technology experiences, enabling Enterprises, Associates, and the Society to Rise. It has 150,000+ professionals working for 1000+ Global Customers (including Fortune 500 companies) in 90 Countries. We’re part of the esteemed Mahindra group, headquartered in India. Under a new CEO, Tech Mahindra is committed to a transformative journey with 'Scale @ Speed' as our guiding principle.

About the Role and Job:

Role: Material Flow Engineer

Location: Pittsburgh, PA

Key Responsibilities (High Level):

• End-to-end warehouse and material flow design
• Buffer analysis and planning
• Material handling equipment evaluation and procurement
• Cart design and procurement
• Lineside and finished goods buffer planning
• Aisle sizing and optimization

Essentially, candidate should be able to take ownership of the complete warehouse design and material flow operations.

Detail JD:

What You’ll Do

• Own the full lifecycle of material flow and process equipment — from concept development and detailed engineering design through industrialization, commissioning, and handover to operations.
• Design, develop, and deploy automated and semi-automated material flow systems (AGV, AMR, A VRC, conveyors, robotic cells, lifts, ASRS) that enable safe, efficient, and scalable manufacturing operations.
• Specify mechanical, electrical, and control system requirements, ensuring compliance with factory layout constraints, safety standards, and ergonomic guidelines.
• Develop system architecture, capacity, and throughput models to validate technical feasibility, balance OPEX and CAPEX, and align with factory growth and production strategies.
• Collaborate cross-functionally with Manufacturing, Operations, Controls, Facilities, Process, and Industrial Engineering teams to integrate automation with MES, WMS, and PLC-based control systems.
• Demonstrate advanced material flow and automation design expertise, mastering AMR/AGV/Atechnologies, conveyance systems, VRCs, docking systems, robotics, and line balancing to optimize throughput and manufacturing flow.
• Lead end-to-end program management, including scope definition, vendor selection, RFQ development, procurement, FAT/SAT, schedule tracking, budget oversight, and milestone reporting.
• Build and execute Discrete Event Simulation (DES) models using tools like FlexSim to evaluate capacity, material flow, and resource utilization.
• Partner cross-functionally with Operations, Engineering, Supply Chain, and Finance teams to align modeling, simulation, and planning activities.
• Deliver data-driven insights and simulation-based recommendations to enable strategic and operational decision-making across the organization.
• Define and standardize fleet management, path optimization, and traffic control strategies for AGV/AMR systems to ensure robust and scalable factory automation.
• Analyze performance data (OEE, throughput, downtime) to identify bottlenecks and drive continuous improvement in flow efficiency, reliability, and automation performance.
• Implement corrective actions and continuous improvement initiatives to enhance uptime, safety, and scalability in high-volume manufacturing environments.
• Serve as a technical mentor and subject-matter expert (SME) in automation and material handling, advising leadership on technology roadmaps and long-term automation strategy.

What You’ll Bring

• Bachelor’s or master’s degree in Industrial or Mechanical Engineering (or a related technical field).
• 5+ years of experience in manufacturing, automation, or material handling engineering within high-volume or logistics environments.
• Proven expertise in AGV, AMR, A VRC, conveyors, robotics, and ASRS design, integration, and commissioning.
• Strong proficiency in AutoCAD, SolidWorks, and factory simulation/flow modeling tools such as FlexSim or equivalent.
• Knowledge of simulation and digital twin tools (FlexSim or equivalent) for flow analysis and predictive optimization.
• Demonstrated ability to lead projects end-to-end — from concept and design through installation, commissioning, and production readiness.
• Skilled in program management, including scope, schedule, budget control, and vendor coordination across complex manufacturing projects.
• Solid understanding of controls integration (PLC/MES/WMS) and industrial safety standards (ANSI/ISO/IEC).
• Strong knowledge of Lean Manufacturing, PFEP (Plan for Every Part), Just-in-Time (JIT), and continuous improvement methodologies.
• Proven ability to interpret and act on manufacturing KPIs (OEE, throughput, yield, downtime) to drive measurable efficiency gains.
• Exceptional analytical, communication, and leadership skills, with the ability to align cross-functional teams toward common goals.

Preferred Qualifications

• Proficiency in data analytics and visualization tools such as Python, SQL, Power BI, or Tableau for equipment performance monitoring and reporting.
• Exposure to IoT-enabled automation systems for real-time equipment monitoring and performance tracking.
• Strong problem-solving mindset and continuous improvement orientation.
• Demonstrated project management experience including budgeting, scheduling, and vendor collaboration.
• Six Sigma Green Belt or Lean Manufacturing certification.
• Experience in battery manufacturing, energy storage, or other high-tech manufacturing environments