Material Flow Engineer

Ford Motor • Dearborn, MI

1d • Onsite

About The Position

The Material Flow Engineer works cross-functionally with Manufacturing Engineering, Plant MP&L, Production, Supply Chain, Packaging, Industrial Engineering, Ergonomics, Safety, Facilities, Purchasing, suppliers, and equipment integrators. The role delivers material-flow solutions from early program development through launch and operational handoff. It translates product and manufacturing assumptions into safe, efficient, cost-effective, plant-executable systems, engineering the people, processes, equipment, facilities, space, inventory, data, and automation needed to move parts from dock to point of fit and transition the system into production.

The position develops end-to-end material-flow strategies and supporting layouts, data, labor plans, equipment requirements, inventory and replenishment approaches, and operating concepts. It evaluates capacity, safety, ergonomics, cost, productivity, and flexibility, using data analysis and simulation where appropriate. The engineer leads deliverables through program milestones, installation, launch, production stabilization, and handoff, while driving continuous improvement.

The role is a salary-grade 6, 7, or 8 position. The listed salary ranges are $72,480–$121,440 for grade 6, $84,480–$141,360 for grade 7, and $96,720–$162,120 for grade 8. Visa sponsorship is unavailable. Candidates must be legally authorized to work in the United States.

Requirements

• Bachelor's degree in Manufacturing or Industrial Engineering, Supply Chain, Logistics, Operations, or a related field, or an equivalent combination of relevant education and experience.
• Experience in manufacturing, material flow, logistics, industrial engineering, supply chain, or a related field; no specific number of years is stated.
• Strong analytical, problem-solving, project-management, and communication skills.
• Ability to work effectively across manufacturing and engineering organizations and influence without direct authority.

Nice To Haves

• Bachelor's degree in Industrial, Manufacturing, Mechanical, or a related engineering discipline.
• Automotive manufacturing or new-model launch experience.
• Experience with Value Stream Mapping, PFEP, AutoCAD, Lean material flow, plant layouts, labor analysis, and material-handling equipment.
• Experience with PMHVs, AGVs, AMRs, ASRS, conveyors, or material-handling automation.
• Experience with material-flow simulation, data analytics, or Power BI.
• Experience developing capital requirements, business cases, or economic evaluations.
• Demonstrated leadership working with cross-functional manufacturing teams.

Responsibilities

• Develop and implement end-to-end material-flow strategies from receiving docks through storage, marketplaces, kitting, sequencing, and production point of fit.
• Develop and maintain Plan for Every Part (PFEP) data to determine packaging, storage, inventory, replenishment, equipment, and floor-space requirements.
• Support Cycle Line Layout (CLL) development and validate workstation material presentation and replenishment feasibility.
• Design marketplaces, sequencing and kitting areas, line-side storage, material routes, and other logistics operating areas.
• Develop floor-space and capacity analyses and integrate material-flow requirements into plant layouts using tools such as AutoCAD.
• Define manual and powered material-handling requirements, including PMHVs, forklifts, tuggers, AGVs, AMRs, conveyors, and other automation technologies.
• Develop material-handling labor requirements, replenishment routes, delivery frequencies, standardized work, and operating concepts.
• Establish inventory, storage, call/card, and replenishment strategies that support production while minimizing material handling and excess inventory.
• Analyze pedestrian and material-handling traffic, congestion, safety, and ergonomic risks, and develop practical countermeasures.
• Develop equipment, facility, labor, and investment requirements and evaluate alternatives based on safety, quality, delivery, cost, productivity, and operational flexibility.
• Use data analysis and simulation, where appropriate, to evaluate capacity, routes, fleet requirements, storage, congestion, and automation opportunities.
• Lead material-flow deliverables through program milestones, installation, launch, production stabilization, and plant operational handoff.
• Drive continuous improvement by reducing material touches, travel distance, floor-space requirements, inventory, labor, and material-handling waste.

Benefits

• Immediate medical, dental, and prescription drug coverage.
• Flexible family care, parental leave, new parent ramp-up programs, and subsidized back-up childcare.
• Family-building benefits, including adoption and surrogacy expense reimbursement and fertility treatments.
• Vehicle discount program for employees and family members, and management leases.
• Tuition assistance.
• Established and active employee resource groups.
• Paid time off for individual and team community service.
• Paid holidays, including the week between Christmas and New Year’s Day.
• Paid time off and the option to purchase additional vacation time.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level