Process Improvement Engineer

Courtyard Inc.•Bear, DE

19h•Remote

About The Position

Courtyard.io is hiring a Process Improvement Engineer to architect and optimize the operation of its vault and logistics network as it scales. The role owns the design of workflows, facility layouts, labor models, and material flow across receiving, intake, storage, picking, packing, and shipping. The engineer will apply engineering methods, data, and systems thinking to increase throughput, reduce cost per unit, improve accuracy, and support expansion into new vaults. The role works closely with Vault Operations, Engineering, and Product to translate operational needs into scalable systems, automation, and infrastructure. It combines physical operations and systems design to help Courtyard increase volume and product categories without adding unnecessary complexity, cost, or risk. The person must live within commuting distance of Bear, Delaware.

Requirements

At least 5 years of experience in process improvement engineering, industrial engineering, logistics engineering, or similar roles.
Hands-on experience in fulfillment centers, warehouses, or logistics networks.
Strong foundation in process engineering, workflow design, and operational modeling.
Comfort using data to drive decisions, including throughput modeling, capacity planning, and cost analysis.
Ability to operate at both strategic and ground level by designing systems and validating them on the floor.
Strong cross-functional communication skills with technical and non-technical teams.
Builder mentality and comfort operating in ambiguity.
Must live within commuting distance of Bear, Delaware.

Nice To Haves

Experience with warehouse systems, automation, or facility design.
Experience supporting facility launches, layout design, and automation initiatives.

Responsibilities

Engineer end-to-end workflows across receiving, intake, storage, picking, packing, and shipping to optimize throughput, accuracy, labor efficiency, and space utilization.
Define standard operating models and performance benchmarks across vaults.
Develop labor standards, capacity models, and staffing plans tied to volume forecasts.
Design warehouse and vault layouts, including slotting strategy, workstation design, travel paths, and material flow.
Support long-term network planning and new vault design, including throughput modeling and space requirements.
Lead operational design for new facility launches from concept through stabilization.
Evaluate, model, and implement automation and tooling, including scanning workflows, conveyor systems, sortation, robotics, and WMS enhancements.
Partner with Engineering and Product to design operational systems, data models, and tooling that reflect real-world workflows.
Translate operational requirements into technical specifications and system design inputs.
Build and analyze operational models to identify bottlenecks, constraints, and cost drivers.
Define KPIs and instrumentation to measure flow, productivity, quality, and utilization.
Run experiments and pilots to validate improvements before scaling.
Lead improvement initiatives from design through implementation and adoption.
Produce SOPs, training materials, and engineering documentation to support consistency.
Act as the technical bridge between floor operators and software and product teams.