Senior Industrial Engineer

Ultimate Staffing; Durham (NC); On-site; USD 95,000 - 130,000; Full time

Job summary

Ultimate Staffing Services seeks a Senior Industrial Engineer for a 1.1 million square foot North Carolina facility, manufacturing American rare-earth magnets for defense, aerospace and automotive sectors. You will own the master layout, capacity planning and total factory flow to meet scaling targets.

Responsibilities include line balancing, Yamazumi charts, VSM, 5S and Kaizen, plus cross-functional collaboration to optimize space, safety and workflow across the plant.

Qualifications

• Education: Industrial Engineering degree with relevant experience.
• Greenfield factory setup experience preferred.
• Experience with Yamazumi charts, VSM, and line balancing.

Responsibilities

• Own and optimize the master factory layout and space allocation.
• Conduct capacity and cycle time analyses to meet scaling targets.
• Design material flow, simulate AGV traffic, and improve bottlenecks.
• Develop line balancing and Lean tools to improve workflow.
• Estimate headcount and labor needs for plant expansion.
• Collaborate cross-functionally to incorporate space and utility needs.
• Implement 5S, visual management, and Kaizen to drive continuous improvement.
• Design layouts, cycle times, and material flow simulations.
• Assess risk and safety in workflows and ensure quality checks.

Skills

5S

Kaizen

Lean methods

Education

Bachelor's degree in Industrial Engineering

Master's degree in Industrial Engineering

Tools

AutoCAD

Simulation software

Job description

Location: Research Triangle Park, NCSalary: $95-$130/kUltimate Staffing Services is actively seeking an experienced Senior Industrial Engineer to join their client's innovative team located in North Carolina. This role is an exciting opportunity to be part of a dynamic company that focuses on manufacturing American rare-earth permanent magnets for critical industries such as defense, aerospace, and automotive. The Senior Industrial Engineer will play a pivotal role in the expansion of a massive 1.1 million square foot manufacturing facility, ensuring the master layout, capacity planning, and total factory flow are optimized to meet scaling targets.

Responsibilities

• Master Factory Layout & Space Allocation: Own and optimize the complete facility layout, ensuring efficient placement of production lines and support infrastructure.
• Capacity & Cycle Time Analysis: Conduct thorough analyses to identify bottlenecks and ensure the factory meets its scaling targets.
• Material Handling & Flow Simulation: Design and simulate material logistics, including AGV traffic and operator walk paths.
• Line Balancing & Lean Tools: Develop Yamazumi charts, line balance tables, and value stream maps to enhance workflow efficiency.
• Headcount & Direct/Indirect Labor Estimates: Create data-driven models for staffing requirements as the plant scales.
• Cross-Functional Collaboration: Collaborate with various teams to incorporate spatial and utility needs into the master plan.
• Continuous Improvement Culture: Implement 5S, visual management, and Kaizen frameworks to foster a culture of continuous improvement.
• Process Design: Develop layouts, cycle times, and material flow simulations to optimize operations.
• Risk & Safety: Conduct ergonomic assessments and safety planning for workflows.
• Quality & Control: Provide input on standard work combinations and quality check visual management.

Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business.

Qualifications

• Education & Experience: Bachelor's degree in Industrial Engineering or related discipline with 5+ years of experience, or a Master's degree with 3+ years of experience.
• Greenfield Factory Setup: Proven experience in setting up large-scale manufacturing facilities.
• IE Tool Proficiency: Expertise in developing Yamazumi charts, VSM, and line balancing.
• Simulation & CAD Mastery: Experience using simulation software and AutoCAD for spatial layouts.
• Data-Driven Problem Solving: Strong background in statistical analysis for machine and operator efficiency.
• Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.
• Preferred QualificationsExperience in large-scale facilities or industries such as automotive or aerospace.
• Six Sigma Green Belt or Black Belt certification.
• Familiarity with specialized storage systems and regulations.
• Experience in regulated industries like Defense, Aerospace, or Automotive.

All qualified applicants will receive consideration for employment without regard to race, color, national origin, age, ancestry, religion, sex, sexual orientation, gender identity, gender expression, marital status, disability, medical condition, genetic information, pregnancy, or military or veteran status. We consider all qualified applicants, including those with criminal histories, in a manner consistent with state and local laws, including the California Fair Chance Act, City of Los Angeles' Fair Chance Initiative for Hiring Ordinance, Los Angeles County Fair Chance Ordinance, and San Francisco Fair Chance Ordinance.