Senior Industrial Engineer

About the role

Greene Resources is seeking a Senior Industrial Engineer to join a growing and dynamic team in Durham, NC. Relocation assistance may be provided for qualified candidates relocating to the Durham, NC area!

Responsibilities

• Own the complete facility layout and space allocation across the 1.1M sqft footprint.
• Optimize the placement of production lines, raw material storage, shipping/receiving, and support infrastructure for optimal workflow.
• Conduct deep-dive capacity analyses and equipment cycle time studies to identify bottlenecks, calculate overall factory throughput, and ensure the site meets its aggressive scaling targets.
• Design the overall Plan for Every Part (PFEP) and internal material logistics. Run discrete-event simulations to model material movement, AGV traffic, forklift operations, and operator walk paths across the factory.
• Create and maintain Yamazumi charts (operator workload balancing), line balance tables, and value stream maps to eliminate non-value-added time and optimize human-machine interactions.
• Develop data-driven headcount models for various production volumes, calculating both direct labor and indirect support staff requirements as the plant scales.
• Partner directly with Process, Equipment, Quality, and Operations teams to understand and incorporate their specific spatial and utility needs into the master plan.
• Lay the groundwork for 5S, visual management, and continuous improvement (Kaizen) frameworks before mass production begins.
• Develop, review, or manage the following deliverables:
• Process Design: Line Layouts (AutoCAD/FactoryCAD), Bill of Process (BOP), Station Cycle Times, Yamazumi Charts, and Material Flow Simulations.
• Risk & Safety: Ergonomic Assessments, Egress/Aisle Safety planning, and workflow PFMEA inputs.
• Quality & Control: Input on standard work combinations, quality check visual management, and station checklists.
• Operations & Maintenance: Staffing plans, work measurement standards, operator standard work instructions, and space allocation matrices.

Requirements

• Proven, hands-on experience actively setting up a new, large-scale manufacturing facility from the ground up from an Industrial Engineering standpoint.
• Must be able to share high-level examples of successful scaling projects.
• Expert capability in developing Yamazumi charts, Value Stream Mapping (VSM), line balancing, and calculating takt times vs. cycle times.
• Direct experience using advanced discrete-event simulation software (e.g., FlexSim, Arena, Simio) to model complex factory flows, alongside proficiency in AutoCAD for massive spatial layouts.
• Strong background using statistical analysis to calculate machine standard minutes, operator efficiency, and equipment utilization rates.

Qualifications

• Bachelor’s degree in Industrial Engineering, Systems Engineering, or a related technical discipline with 5+ years of experience OR a Master’s degree with 3+ years of experience.