Senior Process Analyst, Warehouse & Distribution

Johnson & Johnson•Irving, TX

6d•Hybrid

About The Position

The Senior Process Analyst is responsible for identifying, analyzing, and implementing opportunities to improve warehouse performance, productivity, service levels, cost efficiency, and process reliability. This role uses data, Lean principles, logistics system insights, and cross-functional collaboration to optimize core distribution processes including receiving, put-away, replenishment, picking, packing, shipping, inventory control, returns, and value-added services. The role serves as a key partner to Warehouse Operations, Engineering, Quality, Finance, IT, Planning, Transportation, and Facilities Management partners to translate operational data into actionable improvements. The Senior Analyst will support daily performance routines, continuous improvement initiatives, automation opportunities, standard work, and strategic projects that enable safe, compliant, efficient, and customer-focused warehouse operations.

Requirements

Bachelor’s degree in Supply Chain, Operations Management, Industrial Engineering, Business Analytics, Logistics, Engineering, or a related field required; advanced degree preferred.
A minimum of 4 or more years of experience in warehouse operations, distribution, logistics, supply chain analytics, process improvement, industrial engineering, or related operational roles is required.
Experience working in a regulated, complex, or high-volume distribution environment preferred.
Experience with warehouse management systems, ERP systems, data visualization tools, and process improvement methodologies preferred.
Lean Six Sigma Green Belt, APICS, project management, or related certification preferred.
Strong analytical capability with the ability to interpret complex data, identify root causes, and convert findings into practical operational actions.
Advanced proficiency with Excel and experience with tools such as Power BI, Tableau, Alteryx, SQL, SAP, warehouse management systems, or labor management systems.
Knowledge of warehouse processes including receiving, put-away, replenishment, slotting, picking, packing, shipping, returns, inventory control, and value-added services.
This role may require occasional travel (less than 10%).
The role operates in both office and warehouse environments and will require time on the warehouse floor to observe processes, conduct studies, support implementation, and engage with operations teams.

Nice To Haves

Advanced degree preferred.
Experience working in a regulated, complex, or high-volume distribution environment preferred.
Experience with warehouse management systems, ERP systems, data visualization tools, and process improvement methodologies preferred.
Lean Six Sigma Green Belt, APICS, project management, or related certification preferred.

Responsibilities

Develop, maintain, and improve warehouse performance dashboards, scorecards, and reporting routines for key metrics such as productivity, order cycle time, on-time shipment, inventory accuracy, pick/pack accuracy, dock performance, labor utilization, cost per order, cost per line, and rework. Operations scope includes inbound, domestic outbound, international/export outbound, and domestic returns.
Analyze operational data from warehouse management systems, transportation systems, ERP systems, labor management tools, and manual inputs to identify trends, root causes, bottlenecks, and improvement opportunities.
Translate data insights into clear recommendations, business cases, and action plans for warehouse leadership and cross-functional stakeholders.
Support performance reviews, daily management systems, monthly business reviews, and leadership updates with accurate, timely, and actionable analysis.
Lead or support continuous improvement initiatives focused on reducing waste, improving flow, increasing throughput, reducing damage/defects, and improving service reliability.
Apply Lean, Six Sigma, root cause analysis, process mapping, time studies, and standard work methodologies to improve warehouse processes.
Partner with operations leaders, engineering & process excellence partners and frontline teams to evaluate current-state processes, design future-state workflows, pilot improvements, and sustain results.
Identify opportunities to improve slotting, replenishment logic, pick path efficiency, labor balancing, dock scheduling, inventory control routines, returns processing, and value-added service workflows.
Partner with IT, Engineering, Operations, and external partners to improve warehouse system functionality, reporting accuracy, and digital tools.
Support automation, robotics, warehouse management system enhancements, labor management tools, and self-service analytics capabilities.
Define business requirements, validate data outputs, support user acceptance testing, and assist with deployment of process or system changes.
Create and maintain standard operating procedures, work instructions, training materials, and process documentation to support consistent execution.
Lead or support warehouse efficiency projects from opportunity identification through implementation, including project planning, stakeholder alignment, milestone tracking, risk management, and benefits validation.
Collaborate with Warehouse Operations, Quality, Planning, Transportation, Finance, Customer Service, Engineering, IT, and Facilities partners to deliver aligned solutions.
Support cost improvement projects, capacity planning, labor planning, productivity initiatives, and operational readiness for new products, new processes, or network changes.
Communicate project status, risks, decisions, and results to leaders and stakeholders in a clear and structured manner.
Directly manage project/investment tracking and purchase orders through gCraft, Planisware and related systems.
Align with applicable quality, safety, regulatory, security, audit, and internal control requirements.
Partner with Quality and Operations to investigate process deviations, service incidents, inventory variances, and recurring defects; support corrective and preventive actions.
Promote a culture of safety, compliance, continuous improvement, and data-driven decision making across warehouse operations.
Maintain accurate documentation and evidence of process changes, approvals, training, and benefits realization as required.