Material Handling Automation Execution Engineer

About the role

We are seeking a Material Handling Automation Engineer to drive the deployment of next-generation automation across our manufacturing network.

Responsibilities

• Lead deployment of material handling automation technologies (AMRs, AFTs, ASRS, kitting/sequencing systems) from early concept through launch.
• Identify and evaluate automation opportunities in partnership with Automation Solutions and plant teams to reduce waste, indirect labor, and variability in material flow.
• Conduct labor studies using GMOS and analyze indirect material movement with Assembly Plant Industrial Engineers to quantify benefits and define automation scope.
• Determine unit counts and routing strategies for automation assets and commodities based on operational requirements, volume, and constraints.
• Develop and review layouts using simulation and layout tools to optimize material flow paths, buffer strategies, and equipment utilization.
• Collaborate with Simulation and Vertical Teams to validate concepts, run what-if scenarios, and de-risk execution prior to launch.
• Optimize end-to-end material flow through automation and contribute to future-state process designs, roadmaps, and standards.
• Develop timing- and cost-conscious automation plans, including feasibility, phasing, and alignment with plant launch / shutdown windows.
• Partner with Material Execution Leads, Manufacturing Innovation, and Engineering Center Leads to drive continuous improvement and standardization.
• Engage with strategic suppliers and integrators to define requirements, review designs, and ensure on-time, on-budget execution.
• Support deployment issue resolution related to containerization, logistics, and GPSC interfaces to ensure robust material availability and flow.
• Support feasibility studies, cost-benefit analyses, and ROI modeling to prioritize automation investments and support business cases.
• Cover internal stakeholders (Product Engineering, Manufacturing Operations, IT) to ensure seamless system and data integration.
• Support development and management of launch documentation including PMP plans, PCP assignments, JES/TIS revisions, and ULOC/DLOC and CMA coordination.

Qualifications

• 3+ years of experience in automotive manufacturing, automation deployment, or material flow / industrial engineering.
• Hands-on experience implementing or integrating at least one of the following: – Autonomous Mobile Robots (AMRs) with fleet management systems. – Automated Fork Trucks (AFTs) with safety-rated navigation and control systems. – Automated Storage and Retrieval Systems (ASRS) with warehouse control software.
• Proficiency with labor analysis tools (e.g., GMOS) to conduct indirect labor studies and quantify automation impact on material movement.
• Experience with layout and flow optimization tools (e.g., AutoCAD, Siemens Tecnomatix, FlexSim) for evaluating and redesigning material routes and storage strategies.
• Familiarity with PLC programming, robotic cell integration, and industrial communication protocols (e.g., OPC UA, Modbus, Ethernet/IP).
• Ability to develop and manage launch and process documentation, including PMP plans, PCP assignments, JES/TIS revisions, and ULOC/DLOC and CMA coordination.
• Strong analytical and problem-solving skills for feasibility studies, cost-benefit analyses, and ROI modeling for automation projects.
• Demonstrated success working with cross-functional teams and supporting issue resolution involving containerization, logistics, and supplier partners.
• Bachelor’s degree in Mechanical Engineering, Industrial Engineering, Robotics, or a related technical field, or equivalent experience.
• Comfortable with 25–50% travel, including periodic on-site support and collaboration with cross-functional teams.

Preferred Qualifications

• Experience with digital twin modeling, simulation environments, or virtual commissioning of automation systems.
• Familiarity with Factory of the Future concepts, including AI-driven material flow, predictive analytics, and smart warehousing.
• Background supporting launch planning in unionized manufacturing environments, including safety integration and ergonomic assessments.
• Knowledge of robotic and automation safety standards (e.g., ANSI/RIA R15.06, ISO 10218) for collaborative and autonomous systems.
• Experience collaborating with external automation vendors and integrators to co-develop custom material handling solutions.
• Proficiency in data visualization tools (e.g., Power BI, Tableau) to track automation KPIs and present performance metrics to stakeholders.
• Demonstrated ability to thrive in fast-paced, high-variability manufacturing environments and contribute innovative, practical automation solutions.