Senior Material Flow Engineer

Skydio•Hayward, CA

2d•$127,500 - $210,000

About The Position

Skydio is seeking a talented and driven Material Flow Engineer to design, implement, and continuously improve material flow systems that support the production of our current and next generation of products. In this role, your contributions will drive inventory accuracy, production efficiency, space utilization, and operational scalability across manufacturing and warehouse operations.

Requirements

Experience developing and implementing material flow systems in a manufacturing environment, from new product introduction through high-volume production.
Strong knowledge and hands-on experience with Plan for Every Part (PFEP) development and maintenance.
Experience designing facility layouts, warehouse layouts, supermarket locations, and point-of-use material delivery systems.
Expertise in inventory management principles including min/max inventory planning, Kanban systems, safety stock calculations, and replenishment methodologies.
Experience leading cycle counting programs, inventory audits, and inventory accuracy improvement initiatives.
Strong analytical skills with the ability to evaluate material flow data and develop actionable improvements.
Familiarity with Lean Manufacturing principles including value stream mapping, waste reduction, visual management, and continuous improvement methodologies.
Experience with warehouse management systems (WMS), ERP/MRP systems, and inventory control processes.
Ability to develop and interpret process maps, facility layouts, and material flow diagrams using CAD or similar tools.
Proficiency with data analysis tools such as Excel, SQL, Power BI, or Python.
Enthusiasm for hands-on development and implementation of creative solutions to complex operational challenges.
Flexibility to support production operations, inventory audits, and occasional off-shift activities as needed.
Obtaining FAA Part 107 certification within the first 60 days of employment is strongly encouraged for all Skydio employees and required for certain positions.

Responsibilities

Design, implement, and sustain material flow processes that ensure efficient delivery of materials to production while minimizing waste and inventory risk.
Develop and maintain a comprehensive Plan for Every Part (PFEP) to optimize material storage, transportation, replenishment, and point-of-use delivery strategies.
Analyze and improve facility and production layouts to optimize material movement, reduce travel distances, improve ergonomics, and maximize space utilization.
Establish and manage min/max inventory strategies, Kanban systems, and replenishment methodologies to ensure material availability while minimizing excess inventory.
Partner closely with production, supply chain, manufacturing engineering, and warehouse teams to identify and resolve material flow constraints that impact production performance.
Lead cycle count programs and inventory accuracy initiatives, driving root cause analysis and corrective actions to improve inventory integrity.
Develop material flow capacity models and support warehouse and manufacturing expansion projects to meet future production requirements.
Utilize Lean Manufacturing principles and data-driven analysis to identify opportunities for continuous improvement in inventory management, material handling, and warehouse operations.
Collaborate cross-functionally with supply chain, planning, finance, and operations teams to improve inventory turns, reduce working capital, and increase operational efficiency.
Support new product introductions by developing material flow plans, storage solutions, and replenishment strategies that enable successful production ramp-up.
Develop standard work, visual management tools, and operating procedures to ensure consistent execution of material flow processes.