Senior Advanced Manufacturing Engineer - Material Flow Optimization

Generac; Waukesha (WI); On-site; USD 80,000 - 100,000; Full time

Job summary

Generac, located in Waukesha, Wisconsin, is seeking a Senior Industrial Engineer to drive point of use material flow strategies. The ideal candidate will lead PFEP implementations and optimize material handling systems to enhance productivity and reduce waste.

This role requires a Bachelor's degree in Engineering or Industrial Technology and at least 5 years of relevant experience. Join us to improve manufacturing processes with your expertise!

Qualifications

• 5 years related experience in the Engineering function within a similar working environment.

Responsibilities

• Lead the creation and implementation of PFEP databases for manufacturing operations.
• Design and optimize end-to-end material flow processes.
• Implement material handling systems and optimize production layouts.
• Apply Lean principles to material flow.

Skills

Material Planning & Handling

Lean principles

Data-driven decision making

Cross-functional collaboration

Education

Bachelor’s degree in Engineering or Industrial Technology

Tools

ERP/MRP systems (SAP, Oracle)

Job description

Overview

A Senior Industrial Engineer with expertise in Material Planning & Handling (MPH) and PFEP execution drives point of use material flow strategy, ensuring the right material is delivered in the right quantity, at the right time, and at the lowest total cost. This role is critical in advanced manufacturing environments, directly impacting productivity, layout optimization, and production stability.

Responsibilities

• Lead the creation and implementation of PFEP databases for complex manufacturing operations.
• Designed material replenishment strategies (kanban, min/max, milk-run, JIT).
• Ensured PFEP alignment with production takt time, line-side consumption and replenishment from HUB/Warehouse
• Develop required PFEP tools, train plant engineers for effective use.
• Designed and optimized end-to-end material flow processes from receiving/warehouse to line-side delivery.
• Developed line feeding strategies (kitting, sequencing, point-of-use stocking).
• Implemented material handling systems (tuggers, AGVs, conveyors, manual systems).
• Optimized production layouts for efficient material movement.
• Reduced touchpoints, travel time, and material handling waste.
• Supported NPI (New Product Introduction) by defining material flow and PFEP early in the design phase
• Applied Lean principles (5S, value stream mapping, waste elimination) to material flow
• Implemented or enhanced PFEP using ERP/MRP systems (SAP, Oracle, etc.).
• Partnered with operations, supply chain, engineering, and quality teams.
• Led cross-functional workshops for PFEP rollout and material flow redesign.
• Provided training to manufacturing and logistics teams on standard material processes.
• PFEP development & governance
• Material flow design & optimization
• Line-side delivery systems
• Lean manufacturing & continuous improvement
• Data-driven decision making
• Cross-functional collaboration

Qualifications

• Bachelor’s degree in Engineering or Industrial Technology
• 5 years related experience in the Engineering function within a similar working environment.