Material Flow Engineer (Factory Warehouse Design and Material Flow)

ALTEN Technology USA; United States; On-site; USD 90,000 - 140,000; Full time

Job summary

ALTEN Technology USA seeks a Material Flow Engineer to optimize material handling systems across manufacturing operations, from concept through commissioning, integrating PFEP, AGVs, AMRs, conveyors, and ASRS solutions.

You will collaborate with Manufacturing, Operations, Supply Chain, Facilities, Controls, and IE teams to improve OEE, throughput, and bottlenecks, using tools like AutoCAD, SolidWorks, FlexSim, Python, SQL, Power BI, and Tableau.

Qualifications

• Bachelor’s degree in Industrial Engineering, Mechanical Engineering, or a related technical field.
• 5+ years of experience in manufacturing, automation, material handling, warehouse design, or logistics engineering environments.
• Experience designing and implementing material flow systems including AGVs, AMRs, AGCs, conveyors, robotics, VRCs, and ASRS technologies.
• Strong end-to-end warehouse design, material flow analysis, and factory logistics optimization.
• Experience with PFEP strategies and lineside inventory planning.
• Experience evaluating material handling equipment procurement and commissioning.
• Knowledge of PLC, MES, and WMS integrations.
• Proficiency with AutoCAD, SolidWorks, FlexSim; Python/SQL/Power BI/Tableau preferred.
• Excellent communication, leadership, and cross-functional collaboration skills.

Responsibilities

• Own the full lifecycle of material flow and equipment from concept through commissioning and handoff.
• Design and implement automated material handling systems (AGVs, AMRs, conveyors, robotic cells, ASRS).
• Develop system architectures, throughput models, capacity analyses, and business cases for scalable operations.
• Design warehouse layouts, storage, buffers, and flow pathways.
• Manage PFEP strategies for inventory movement, storage, replenishment, and production support.
• Evaluate and procure material handling equipment and automation solutions.
• Build discrete event models to analyze flow, resources, throughput, bottlenecks, and performance.
• Collaborate with cross-functional teams to integrate with MES/WMS/PLC systems.
• Lead project execution: vendor management, RFQs, FAT/SAT, budgeting, milestones.
• Analyze KPIs to identify improvements and drive continuous improvement.

Skills

Proj. management

Cross-functional collaboration

Leadership

KPI analysis

Lean / Six Sigma concepts

Industrial safety standards

Education

Bachelor’s degree in Industrial Engineering, Mechanical Engineering, or related field

Tools

AutoCAD

SolidWorks

FlexSim

Python

SQL

Power BI

Tableau

Job description

We’re ALTEN Technology USA, an engineering company helping clients bring groundbreaking ideas to life—from advancing space exploration and life-saving medical devices to building autonomous electric vehicles. With 3,000+ experts across North America, we partner with leading companies in aerospace, medical devices, robotics, automotive, commercial vehicles, EVs, rail, and more.

As part of the global ALTEN Group—57,000+ engineers in 30 countries—we deliver across the entire product development cycle, from consulting to full project outsourcing.

When you join ALTEN Technology USA, you’ll collaborate on some of the world’s toughest engineering challenges, supported by mentorship, career growth opportunities, and comprehensive benefits. We take pride in fostering a culture where employees feel valued, supported, and inspired to grow.

As a Material Flow Engineer you will be responsible for;

• Owning the full lifecycle of material flow and process equipment from concept development and engineering design through commissioning, startup, and operational handoff.
• Designing, developing, and implementing automated and semi-automated material handling systems including AGVs, AMRs, AGCs, VRCs, conveyors, robotic cells, lifts, and ASRS solutions.
• Developing system architectures, throughput models, capacity analyses, and business cases to support scalable manufacturing operations and future growth.
• Designing and optimizing warehouse layouts, lineside storage, finished goods buffers, aisle configurations, and material flow pathways.
• Managing PFEP (Plan for Every Part) strategies to ensure efficient inventory movement, storage, replenishment, and production support.
• Evaluating, selecting, specifying, and supporting procurement of material handling equipment, carts, automation technologies, and supporting infrastructure.
• Building and executing discrete event simulation models to analyze material flow, resource utilization, throughput, bottlenecks, and operational performance.
• Collaborating with Manufacturing, Operations, Supply Chain, Facilities, Controls, and Industrial Engineering teams to integrate material flow solutions with MES, WMS, and PLC-based systems.
• Leading project execution activities including vendor management, RFQ development, procurement support, FAT/SAT, schedule tracking, budgeting, and milestone reporting.
• Analyzing operational metrics such as OEE, throughput, downtime, and yield to identify improvement opportunities and drive continuous improvement initiatives.
• Developing fleet management, traffic control, and path optimization strategies for AGV and AMR systems.
• Serving as a technical subject matter expert on automation, warehouse design, and material handling systems while supporting long-term automation strategies.

Qualifications

• Bachelor’s degree in Industrial Engineering, Mechanical Engineering, or a related technical field.
• 5+ years of experience in manufacturing, automation, material handling, warehouse design, or logistics engineering environments.
• Proven experience designing and implementing material flow systems including AGVs, AMRs, AGCs, conveyors, robotics, VRCs, and ASRS technologies.
• Strong expertise in end-to-end warehouse design, material flow analysis, and factory logistics optimization.
• Experience with buffer analysis, lineside inventory planning, finished goods storage, and aisle sizing methodologies.
• Hands-on experience developing and managing PFEP (Plan for Every Part) strategies.
• Proficiency with AutoCAD, SolidWorks, FlexSim, or similar simulation and factory modeling tools.
• Experience evaluating, selecting, procuring, and commissioning material handling equipment and automation solutions.
• Strong knowledge of controls integration including PLC, MES, and WMS systems.
• Knowledge of Lean Manufacturing, Just-in-Time (JIT), continuous improvement principles, and industrial safety standards.
• Proven project management experience including vendor coordination, budgeting, scheduling, and implementation oversight.
• Ability to analyze manufacturing KPIs and convert data into actionable operational improvements.
• Experience with Python, SQL, Power BI, Tableau, or similar analytics tools is preferred.
• Excellent communication, leadership, and cross-functional collaboration skills.

Salary Range: $90K - $140K

The actual salary offered is dependent on various factors including, but not limited to, location, the candidate’s combination of job-related knowledge, qualifications, skills, education, training, and experience.

All qualified applicants will receive consideration for employment and will not be discriminated against on the basis of race, color, religion, sex, sexual orientation, gender identity, national origin, disability, protected veteran status, age, genetic information, or pregnancy.

Please beware of job seeker scams and see this important notice on our careers page for more information about our recruiting process.

Compliance Notice: Alten USA is a federal contractor subject to the requirements of the Vietnam Era Veterans’ Readjustment Assistance Act (VEVRAA) and Executive Order 11246. We are an Equal Opportunity Employer and consider all qualified applicants without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or veteran status.

Drug Screening Requirement: As a federal contractor, Alten USA maintains a drug-free workplace. All candidates selected for employment will be required to successfully complete a pre-employment drug screening as a condition of hire.