Senior Analytics Engineer

HCL Technologies Limited; United States; On-site; USD 130,000 - 190,000; Full time

Job summary

Sapsf is seeking an Industrial Engineering Analytics Engineer to lead the development of advanced analytical models that improve manufacturing efficiency, capacity planning, and cost optimization. You will build integrated IE models linking capacity, labor, material flow, PFEP, and COGS to enable data-driven decisions across factory operations.

The role requires strong IE fundamentals, experience with simulation tools (FlexSim/AnyLogic/Simio), and proficiency in Python/SQL plus BI tools to

Qualifications

• Bachelor’s degree in Industrial Engineering, Mechanical Engineering, Operations Research, or a related field.
• 7+ years of experience in industrial engineering analytics, manufacturing modeling, or operations analysis.
• Strong understanding of manufacturing systems, capacity planning, and industrial engineering principles.

Responsibilities

• Develop and own integrated IE models that connect capacity, labor, material flow, PFEP, and cost (COGS) to support factory planning and operations.
• Build and maintain capacity models (target vs. forecast vs. gated capacity), incorporating cycle time, OEE, yield losses, and bottleneck analysis.
• Develop labor models to optimize headcount, utilization, and labor cost across production systems.
• Create and evaluate business cases for capital investments (ROI, IRR, NPV, cost-benefit).
• Lead COGS modeling including labor, overhead, scrap, and process-driven cost components.
• Develop and track scrap and yield models quantifying cost impact and improvement opportunities.
• Design and maintain OEE models (availability, performance, quality) to drive efficiency.
• Perform buffer and WIP analysis to optimize storage and flow.
• Develop PFDs and value stream maps for manufacturing systems.
• Integrate PFEP data into models to optimize material flow and line-side delivery.

Skills

Analytical thinking

Modeling at scale

Cross-functional collaboration

Communication

Project management

Attention to detail

Education

Bachelors in Industrial/Mechanical Engineering or OR

Tools

FlexSim

AnyLogic

Simio

Python

SQL

Power BI/Tableau

Job description

Requisition ID132008-Posted09/16/2026

The Industrial Engineering Analytics Engineer will lead the development and application of advanced analytical models to drive manufacturing efficiency, capacity planning, and cost optimization. This role is responsible for building and managing integrated IE models that connect capacity, labor, material flow, PFEP, and cost (COGS) to enable data-driven decision making across factory and site operations. The ideal candidate will combine strong industrial engineering fundamentals with advanced analytics, simulation, business case development, and AI-driven systems to support large-scale manufacturing environments.

Key Responsibilities

• Develop and own integrated IE models that connect capacity, labor, material flow, PFEP, and cost (COGS) to support factory planning and operations
• Build and maintain capacity models (target vs. forecast vs. gated capacity), incorporating cycle time, OEE, yield losses, and bottleneck analysis
• Develop labor models to optimize headcount, utilization, and labor cost (LOH) across production systems
• Create and evaluate business cases for capital investments, including ROI, IRR, NPV, and cost benefit analysis
• Lead COGS modeling, including labor, overhead, scrap, and process-driven cost components
• Develop and track scrap and yield models, quantifying cost impact and identifying improvement opportunities
• Design and maintain OEE models (availability, performance, quality) to drive operational efficiency and continuous improvement
• Perform buffer and WIP analysis to optimize inline and interline storage, reduce bottlenecks, and stabilize production flow
• Develop process flow diagrams (PFDs) and value stream maps to represent manufacturing systems and identify inefficiencies
• Integrate PFEP (Plan for Every Part) data into models to optimize material flow, storage, and line-side delivery strategies
• Support factory layout, site planning, and material flow decisions through data-driven insights and modeling
• Perform scenario analysis and sensitivity studies to evaluate production strategies and capacity expansion plans
• Utilize and/or develop factory simulation models (e.g., FlexSim, AnyLogic, Simio) to analyze throughput, bottlenecks, and system performance
• Support factory ramp-up, installation, and operational readiness through model validation and performance tracking
• Collaborate with cross-functional teams (Manufacturing, Operations, Supply Chain, Finance, Engineering) to align models with real-world constraints and business needs
• Translate complex analytical outputs into clear, executive-level insights and recommendations
• Collaborate with MES and Controls teams to integrate shop-floor data with IE models, ensuring accurate OEE measurement and enabling real-time, scalable dashboards for operational visibility and executive decision-making AI & Data Systems
• Introduce and implement AI-driven tools and platforms to enhance industrial engineering analytics and decision-making
• Design and manage scalable data models and data architecture for IE, capacity, labor, PFEP, and cost analytics
• Develop standardized systems, frameworks, and governance for data modeling, analytics, and reporting
• Automate data collection, validation, and reporting pipelines using AI and advanced analytics tools
• Enable predictive analytics and intelligent decision-making for capacity, throughput, and cost optimization
• Establish best practices for data quality, model standardization, and system integration across the organization

Skill Requirements

• Strong analytical and problem-solving skills with a data-driven mindset
• Ability to build scalable models and analytics systems that support both tactical and strategic decisions
• Strong communication skills to translate complex data into actionable insights
• Ability to work across cross-functional teams and influence decision-making
• Attention to detail with a systems-level understanding of manufacturing operations
• Ability to manage multiple projects and priorities in a fast-paced environment

• Bachelor’s degree in Industrial Engineering, Mechanical Engineering, Operations Research, or a related field
• 7+ years of experience in industrial engineering analytics, manufacturing modeling, or operations analysis
• Strong understanding of manufacturing systems, capacity planning, and industrial engineering principles

Other Requirements

• Experience building end-to-end IE models integrating capacity, labor, cost, PFEP, and material flow
• Proficiency in capacity modeling, OEE analysis, cycle time studies, and line balancing
• Hands-on experience with PFEP, material flow optimization, and warehouse integration
• Experience with factory simulation tools (e.g., FlexSim, AnyLogic, Simio)
• Strong experience in business case development (ROI, IRR, NPV)
• Knowledge of COGS modeling, cost structures, and financial impact analysis
• Experience with data analysis tools (Excel advanced modeling, Python, SQL, Power BI/Tableau, or similar)
• Familiarity with AI/ML applications in manufacturing analytics (preferred)
• Familiarity with lean manufacturing and continuous improvement methodologies