Staff Engineer, Industrial

Responsibilities

• Lead factory layout development, production line design, and manufacturing system optimization for new and existing programs.
• Plan and execute greenfield manufacturing facilities, including master planning, space allocation, utilities, equipment placement, production flow, and capacity planning.
• Develop scalable manufacturing concepts from initial planning through production launch.
• Optimize material flow, point-of-use storage, supermarkets, kitting, replenishment systems, tugger routes, and warehouse logistics.
• Create detailed 2D factory layouts and 3D manufacturing models covering equipment, utilities, workstations, safety zones, support infrastructure, and expansion plans.
• Perform capacity planning, line balancing, takt-time analysis, labor planning, buffer sizing, bottleneck analysis, time studies, ergonomic assessments, spaghetti diagrams, and workflow analyses.
• Establish standards for material presentation, packaging, FIFO management, visual controls, workstation design, and factory operations.
• Lead cross-functional factory design reviews with Manufacturing Engineering, Operations, Facilities, Supply Chain, Quality, EHS, and Program Management.
• Use discrete-event simulation to model throughput, identify constraints, validate factory designs, and optimize manufacturing strategies.
• Support construction, equipment installation, tape-outs, utility coordination, commissioning, and production readiness for factory launches.
• Drive Lean Manufacturing initiatives including 5S, visual management, standardized work, continuous improvement, and value-stream optimization.
• Maintain factory design standards, launch playbooks, production system guidelines, and manufacturing best practices.

Requirements

• Bachelor's degree in Industrial Engineering, Mechanical Engineering, Manufacturing Engineering, Systems Engineering, or a related technical discipline.
• 8+ years of experience in industrial engineering, factory design, manufacturing systems, production planning, advanced manufacturing engineering, or greenfield facility development.
• Experience designing factory layouts, production lines, and scalable manufacturing systems for complex products.
• Experience supporting greenfield facilities, facility expansions, or major production-line launches.
• Strong knowledge of machining, composites, electrical assemblies, precision mechanical assemblies, and final integration.
• Experience with production ramp-up, new product introduction, and manufacturing process development.
• Ability to lead cross-functional projects in a fast-paced manufacturing environment.
• Strong analytical, communication, project-management, and problem-solving skills.

Preferred Qualifications

• Aerospace, defense, automotive, or advanced manufacturing experience.
• Experience leading greenfield factory development, relocations, or major expansions.
• Knowledge of AS9100, ISO 9001, or other regulated manufacturing environments.
• Experience with automated material handling, robotics, AGVs/AMRs, automated storage systems, or Industry 4.0 technologies.
• Lean Six Sigma Green Belt, Black Belt, or equivalent certification.
• Experience with MES, ERP systems, digital factory technologies, and production simulation software.

Tools and Methods

• AutoCAD, SolidWorks, Revit, Visio, or equivalent CAD/layout software.
• Siemens Plant Simulation, FlexSim, AnyLogic, or equivalent discrete-event simulation software.
• Time studies, MTM/MOST, work measurement, and labor analysis.
• Capacity modeling, line balancing, takt planning, and production system design.
• Lean Manufacturing, Six Sigma, Value Stream Mapping, 5S, Kanban, and visual management.
• Material flow analysis, warehouse and logistics design, and factory master planning.