Material Handling Engineer (KTP)

You will manage the flow and movement of materials through manufacturing facilities to support production operations at Ford Motor Company.

Responsibilities

• Lead end-to-end material flow from receiving docks to point-of-use and shipping for direct and indirect materials. Design and optimize lean material delivery systems, including line-side delivery, warehouse marketplace, kitting, and sequencing. Manage inventory strategy and PFEP (Plan for Every Part), including storage, flow paths, and capacity planning.
• Own the end-to-end Engineering Change Management & Control (ECM/ECC) process for MP&L, ensuring alignment with plant and corporate change management systems. Lead cross-functional coordination for all part, supplier, and process changes. Develop and execute change readiness plans, including inventory burn-down, phase-in/phase-out, cutover timing, and obsolescence mitigation.
• Drive performance improvements through structured problem-solving and kaizen. Lead cost savings initiatives, including labor efficiency, inventory reduction, and space optimization. Apply root cause problem-solving to eliminate waste and variation.
• Implement and support automation solutions, such as AGVs, AMRs, ASRS, and smart conveyance.
• Analyze and improve material handling methods, equipment utilization, and labor balancing. Conduct cycle time analysis, bottleneck identification, and throughput optimization. Design plant layouts, flow paths, and material presentation using CAD and simulation tools. Lead ergonomic assessments and workstation design to improve safety and productivity.
• Ensure system readiness, including ERP/SAP updates, BOM accuracy, routings, packaging specs, labeling, and traceability requirements. Drive launch and program integration, ensuring material flow readiness for new programs, engineering changes, and model year transitions. Identify and mitigate change-related risks.
• Enforce safety standards, ergonomics, and 5S discipline across all material handling operations. Manage resource planning to meet production requirements.
• Strong capability in capacity modeling and constraint-based planning. Advanced proficiency in Excel, Power BI, simulation tools, and CAD (AutoCAD or similar).
• Understanding of launch management and program readiness. Experience integrating automation with labor strategy.

Qualifications

• Bachelor’s Degree
• 5 or more years of experience in Material Planning & Logistics end-to-end Material Flow Management.
• Preferred qualifications include a Bachelor’s Degree in Engineering, certifications associated with Material Handling Automation, and demonstrated experience working with all levels of the organization.