Lead Material Flow Engineer - Material Flow

The Role

Mach Industries is seeking a Lead Material Flow Engineer to develop our internal logistics network to support consistent, on-time delivery of raw materials and WIP enabling high-rate production across Mach’s factories

In this role, you will design and scale end-to-end material flow across multiple product lines and manufacturing sites. This role leads the development of safe, efficient, and traceable processes that move parts and assemblies from suppliers and warehouses to production points of use. Working with Supply Chain, Manufacturing, Production Control, Quality, Engineering, Facilities, and site leadership, you will prepare for next year's production ramp, deliver site-ready solutions, and establish standards that can be deployed consistently across Mach’s enterprise.

Key Responsibilities

• Lead material-flow strategy and implementation for production growth across multiple product lines and sites, from concept and capacity planning through launch, stabilization, and handoff of a fully detailed production plan to Operations.
• Map current and future-state value streams, and build discrete event simulation models to test flow, routing, staging, and capacity decisions before committing capital.
• Develop project plans, budgets, risk assessments, and readiness reviews; communicate status, decisions, and escalations to stakeholders and leadership.
• Coordinate with facilities, construction, and outside line builders, integrators, and equipment suppliers so their designs fit the overall site plan and material-flow requirements.
• Develop a plan for every part (PFEP) covering the full bill of materials for new products, rate increases, and site expansions, defining each part's storage location, packaging, replenishment method, and delivery route.
• Analyze and select the right presentation method for each part (kitting, sequencing, or line-side bulk replenishment such as kanban) based on part size, variety, usage rate, cost, space, labor, ergonomics, and quality risk, then plan the kit and sequence designs, build areas, staging, and delivery cadence.
• Design line-side milk-run routes, delivery frequencies, and schedules, and set line-side stock requirements for each part in hours of coverage, including min/max levels and reorder triggers, balancing delivery cost, route capacity, line-side space, and line-stoppage risk.
• Design and improve inbound receiving and unloading, warehousing, kitting, sequencing, batching, intermediate storage, line-side delivery, point-of-use storage, and returnable-packaging processes.
• Develop handling strategies for the full range of aerospace materials, including large structures, raw stock, shelf-life and temperature-controlled materials such as composites, hazardous materials, and ESD-sensitive electronics.
• Develop cost-effective packaging and part-presentation solutions for manual and automated handling that protect parts from damage, foreign object debris (FOD), and electrostatic discharge (ESD).
• Create detailed facility and line-side material-flow layouts with Manufacturing Engineering and Facilities that support throughput, space, labor, inventory, ergonomics, and production-readiness targets.
• Evaluate and implement material-handling equipment and automation where appropriate, such as conveyors, lift-assist systems, automated storage, mobile robots, and digital tracking tools.
• Use approved data analytics and AI-enabled tools to predict material-flow bottlenecks and optimize throughput in near real time.
• Establish common material-flow standards, metrics, and implementation playbooks while accounting for differences in products, processes, and site capabilities.
• Design material-flow processes that maintain part identification, configuration control, chain of custody, and lot and serial traceability from receipt through point of use, in line with applicable quality and regulatory requirements.
• Define scan and transaction points (barcode, 2D Data Matrix, or RFID) at receiving, putaway, kitting, issue, and line-side consumption so ERP, MES, and WMS records match each part's physical location and lot or serial status.
• Set location control, labeling, cycle-count, and shelf-life standards, including first-expired, first-out (FEFO) rotation and out-time tracking, that sustain inventory accuracy and allow rapid containment of suspect lots or serial numbers.
• Verify that solutions meet safety, quality, delivery, cost, and schedule objectives, monitor performance and drive corrective actions after launch, and support customer, DCMA, and AS9100 audits of material control processes.

Required Qualifications 

• Bachelor's degree in Industrial Engineering, Supply Chain, Manufacturing Engineering, Logistics, or a related field; equivalent experience considered.
• 7+ years of experience in material-flow, manufacturing, logistics, or supply-chain engineering, including work in complex production environments.
• Demonstrated experience taking material-flow solutions from analysis and design through implementation and operational handoff.
• Experience supporting production ramps, new product introductions, or capacity expansions across multiple programs or sites.
• Proficiency with facility and process layout tools, such as AutoCAD or equivalent.
• Hands-on experience building discrete event simulation models with tools such as FlexSim, AnyLogic, Simio, or Siemens Plant Simulation.
• Strong analytical skills, including the ability to use operational data to assess capacity, inventory, labor, space, and throughput.
• Experience with ERP, MRP, MES, WMS, or similar systems and their role in production material control, inventory accuracy, and lot or serial traceability.
• Ability to lead cross-functional projects, manage competing priorities, and communicate recommendations clearly to technical teams and leadership.
• Commitment to safe, high-quality, disciplined execution in a regulated manufacturing environment.

Preferred Qualifications

• Experience in aerospace, defense, or other highly regulated manufacturing environments, or in high-volume automotive manufacturing.
• Familiarity with AS9100 quality systems, counterfeit parts prevention standards (AS5553, AS6174), and requirements for configuration management, traceability, and product preservation.
• Familiarity with defense marking, packaging, and property requirements, such as MIL-STD-129, MIL-STD-130 and item unique identification (IUID), MIL-STD-2073, and government property management.
• Experience supporting ITAR-controlled programs or other export-controlled work, where applicable to the role.
• Master's degree or professional certification in supply chain, industrial engineering, or project management.
• Experience with data visualization or analysis tools such as Power BI, Tableau, or Python.
• Experience with automation, digital material tracking, warehouse optimization, or advanced manufacturing systems.

Additional Requirements

Senior Engineer 140000 - 180000 USD