Material Flow Engineer (Factory Warehouse Design and Material Flow)

ALTEN Technology USA•North Reading, MA

9d•$90,000 - $140,000

About The Position

ALTEN Technology USA is an engineering company that partners with clients across industries including aerospace, medical devices, robotics, automotive, commercial vehicles, electric vehicles, and rail. The company is part of the global ALTEN Group and supports work across the product development cycle. The Material Flow Engineer owns the full lifecycle of material flow and process equipment, from concept development and engineering design through commissioning, startup, and operational handoff. The role designs and implements automated and semi-automated material handling solutions, develops system architectures and analytical models, optimizes warehouse and factory layouts, and supports scalable manufacturing operations. It also includes cross-functional coordination, project execution, equipment procurement and commissioning, performance analysis, and technical leadership on automation and material handling systems. ALTEN offers mentorship, career growth opportunities, and comprehensive benefits. Salary range: $90,000–$140,000; actual compensation depends on factors including location and job-related qualifications, skills, education, training, and experience. The company is an equal opportunity employer and requires successful completion of a pre-employment drug screening for selected candidates.

Requirements

Bachelor’s degree in Industrial Engineering, Mechanical Engineering, or a related technical field.
At least 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.
Excellent communication, leadership, and cross-functional collaboration skills.

Nice To Haves

Experience with Python, SQL, Power BI, Tableau, or similar analytics tools.

Responsibilities

Own the lifecycle of material flow and process equipment from concept development and engineering design through commissioning, startup, and operational handoff.
Design, develop, and implement automated and semi-automated material handling systems, including AGVs, AMRs, AGCs, VRCs, conveyors, robotic cells, lifts, and ASRS solutions.
Develop system architectures, throughput models, capacity analyses, and business cases for scalable manufacturing operations and future growth.
Design and optimize warehouse layouts, lineside storage, finished goods buffers, aisle configurations, and material flow pathways.
Manage PFEP (Plan for Every Part) strategies to support inventory movement, storage, replenishment, and production.
Evaluate, select, specify, and support procurement of material handling equipment, carts, automation technologies, and supporting infrastructure.
Build and execute discrete event simulation models to analyze material flow, resource utilization, throughput, bottlenecks, and operational performance.
Collaborate with Manufacturing, Operations, Supply Chain, Facilities, Controls, and Industrial Engineering teams to integrate material flow solutions with MES, WMS, and PLC-based systems.
Lead project execution activities, including vendor management, RFQ development, procurement support, FAT/SAT, schedule tracking, budgeting, and milestone reporting.
Analyze operational metrics such as OEE, throughput, downtime, and yield to identify opportunities and drive continuous improvement.
Develop fleet management, traffic control, and path optimization strategies for AGV and AMR systems.
Serve as a technical subject matter expert on automation, warehouse design, and material handling systems, and support long-term automation strategies.