Controls Engineer - Manufacturing Engineering

Position Purpose

This position is responsible for designing, optimizing, and sustaining efficient material flow systems across the facility. This includes material presentation, lineside delivery, internal logistics, supermarket design, AGV/tugger routes, PFEP ownership, and integration with fabrication, paint and assembly processes in the plant. This role provides technical leadership across manufacturing engineering, production, logistics, and supply chain teams to ensure material availability, reduce waste, decrease internal logistics costs, and support continuous improvement initiatives.

Major Tasks, Responsibilities & Key Accountabilities

• Material Flow System Design & Optimization
  • Develop and maintain the Plan for Every Part (PFEP) including container strategy, trolleys design, replenishment methods, route frequency, and storage locations.
  • Develop, maintain, and continuously optimize material flow using Material and Information Flow Diagrams (MIFDs) to support efficient manufacturing processes.
  • Design material flow solutions including supermarkets, kitting cells, sequencing strategies, lineside presentation, and internal logistics routes.
  • Lead optimization of material movement using lean principles to eliminate waste and improve flow.
  • Evaluate and implement new technologies (AGVs, AMRs, digital kanban, tugger optimization, point-of-use storage).
• Continuous Improvement & Operational Excellence
  • Lead complex CI initiatives to reduce logistics cost, improve throughput, and stabilize flow to production lines.
  • Conduct time studies, data analysis, and simulation modelling to identify capacity constraints and improvement opportunities.
  • Lead root cause analysis and corrective actions related to material shortages, bottlenecks, and inventory accuracy issues.
• Cross‑Functional Leadership
  • Collaborate with Production, Supply Chain, Procurement, and Industrial Engineering to align material strategies with production plans.
  • Partner with Program Management and NPI teams to develop material flow designs for new products or model introductions.
• Documentation & Standards
  • Ensure accurate and up-to-date documentation including PFEPs, logistics work instructions, replenishment standards, and layout drawings.
  • Create future-state maps and maintain material flow standards across the plant.
• Data & Systems Integration
  • Use ERP/MRP, MES, and logistics systems to maintain accurate material parameters.
  • Analyze inventory data, delivery performance, route metrics, and internal logistics KPIs to drive improvements.
• Other duties as assigned

Minimum Qualifications

• Bachelor's degree in Manufacturing Engineering, Industrial Engineering, Mechanical Engineering, or related field.
• 5–10 years of experience in manufacturing, industrial engineering, logistics engineering, or material flow optimization, preferably in automotive sector.
• Demonstrated expertise in lean manufacturing, PFEP management, value stream mapping, and material flow design.
• Proficiency with CAD tools, layout design, and manufacturing documentation.
• Strong analytical skills and experience with data analysis or simulation tools (Excel, PowerBI, discrete-event simulation preferred).
• Experience working with ERP/MRP systems.
• Excellent communication skills with proven ability to lead cross‑functional teams.
• Must pass any drug screens, background checks, and any pre-employment tests, which will be conducted in accordance with applicable law.

Job Conditions

Manufacturing/factory environment. Subject to noise and temperature changes.

Physical Requirements

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. While performing the duties of this job, the employee is regularly required to:

• Must be able to work flexible schedule, including Friday - Sunday 6am -6pm
• Must be able to regularly lift and/or move up to 10lbs, frequently and/or move up to 35lbs, and occasionally lift and/or move up to 50lbs.
• Must be able to perform continuous, repetitious physical activities. These activities may involve fine movements or large motions.
• Must be able to grasp/pinch small items, reach out and up, and turn wrist.
• Must be capable of keeping pace with current production speed.
• Must be able to push/pull with reasonable force.
• Must be able to perform the following requirements of bending, stooping, climbing, kneeling, and standing for extended periods of time.
• Must be able to work in multiple climates including hot/cold temperatures, and dusty environment.