Logistics Engineer (Lead Logistics Systems & Warehouse Engineer)

Position: Logistics Engineer(Lead Logistics Systems & Warehouse Engineer)

Location: Michigan city, Indiana

Contract - 12+ Months

About the Role

Advanced Manufacturing | SAP EWM | Lean Material Flow

Seeking a highly technical, execution-focused Lead Logistics Systems & Warehouse Engineer to architect, standardize, and optimize end-to-end warehouse and production material flow systems within a high-mix manufacturing environment. This role serves as the engineering authority for warehouse design, SAP-driven inventory architecture, line-side logistics, replenishment engineering, material handling systems, and lean operational transformation.

The ideal candidate will possess advanced expertise in warehouse systems engineering, SAP EWM integration, industrial engineering methodologies, production logistics, inventory control, lean material flow, warehouse optimization, and manufacturing support operations. This role supports high-throughput manufacturing operations through scalable logistics infrastructures, real-time inventory accuracy, optimized material movement, and zero-disruption production support.

Core Responsibilities

Warehouse Systems Engineering & Logistics Architecture

Design and implement lean visual warehouse systems utilizing fixed-bin structures, supermarket replenishment models, FIFO-controlled material flow, point-of-use inventory strategies, flow racks, VMIL/heavy-part staging areas, and standardized warehouse zoning. Develop warehouse slotting strategies based on velocity analysis, BOM frequency, travel-time reduction, cubic utilization, and ABC classification principles.

Establish engineered standards for warehouse aisles, storage systems, forklift traffic flow, tugger routes, dock-to-line movement, operator ergonomics, equipment charging stations, and material presentation systems. Lead warehouse redesign initiatives involving facility layout optimization, throughput balancing, capacity modeling, warehouse consolidation, and material flow simulation.

SAP EWM / ERP Integration & Inventory Control

Own SAP/EWM warehouse alignment including storage types, bin structures, putaway logic, picking strategies, replenishment triggers, warehouse task sequencing, and backflush controls. Establish full digital traceability between physical inventory and SAP warehouse architecture.

Develop standardized SAP transaction workflows supporting receiving, putaway, kitting, production staging, line-side replenishment, cycle counting, inventory reconciliation, and backflush execution. Design BOM-driven pick logic and station-level material allocation methodologies while eliminating transactional discrepancies through engineered inventory control processes and real-time material validation.

Production Logistics & Material Flow Engineering

Architect structured material flow systems from receiving docks through warehouse supermarkets, production supply areas, line-side presentation, replenishment, and reverse logistics/backflush operations.

Engineer replenishment systems utilizing Kanban, two-bin systems, min/max logic, sequenced delivery, milk-run routing, and consumption-based triggers. Define optimal kit sizing and replenishment frequencies through coordination with production scheduling, operations, purchasing, inventory control, and manufacturing engineering teams.

Design scalable line-feeding strategies minimizing WIP accumulation, excess travel, handling touches, operator motion waste, and production downtime while maximizing manufacturing throughput and material availability.

Material Handling

Lead engineering selection and optimization of forklifts, Drexel equipment, tugger systems, flow racks, lift-assist devices, ergonomic material presentation systems, and heavy-part handling equipment.

Analyze and optimize equipment utilization, travel paths, empty travel time, dock utilization, loading efficiency, and material transfer latency. Develop standards for transport systems, material handling constraints, facility traffic patterns, storage density, safety clearances, and ergonomic access zones.

Apply warehouse engineering methodologies including time studies, capacity analysis, motion analysis, spaghetti mapping, value stream mapping, process simulation, and throughput analysis to optimize warehouse and logistics performance.

Lean Enterprise & Continuous Improvement

Drive warehouse transformation initiatives utilizing Lean Manufacturing, Six Sigma, 6S methodology, standardized work, visual factory principles, Kaizen execution, and root cause analysis.

Develop visual management systems including color-coded replenishment controls, KPI dashboards, warehouse performance boards, inventory visibility systems, audit processes, and ownership mapping. Lead continuous improvement projects targeting labor optimization, warehouse space reduction, inventory reduction, throughput improvement, dock-to-stock reduction, and inventory accuracy enhancement.

Develop SOPs, operator training programs, skill matrices, standardized work instructions, and warehouse audit systems supporting operational discipline and continuous improvement.

Required Technical Qualifications

Bachelor's degree in Logistics Engineering, Supply Chain Engineering, Manufacturing Engineering, Operations Engineering.

Minimum 7+ years of progressive experience in warehouse engineering, manufacturing logistics, SAP EWM/WM systems, lean material flow, production logistics engineering, warehouse optimization, and inventory control within high-volume manufacturing environments.

Advanced expertise in SAP EWM/WM/MM, warehouse slotting optimization, BOM-driven material staging, lean replenishment systems, inventory control engineering, warehouse layout optimization, and material flow analysis. Strong technical knowledge of material handling systems, production supply systems, logistics modeling, and facility layout engineering required. Forklift and Drexel operational knowledge preferred.

Preferred Certifications

Lean Six Sigma Green Belt or Black Belt, APICS CPIM/CSCP, SAP EWM certification, OSHA/warehouse safety training, and lean manufacturing certifications preferred.