Process Engineer - Fulfillment Center

Abacus Solutions Group is currently recruiting for a Process Engineer to be based out of a facility in Northeast, MD area. Bilingual in English and Spanish is required!

Summary: Design, analyze, and continuously improve fulfillment and distribution center operations for web (e-commerce) and retail channels. Partner with operations, IT, and supply chain teams to optimize order flow, labor productivity, inventory accuracy, and on-time shipment performance — while maintaining a safe and scalable work environment during both steady-state and peak periods.

Responsibilities:

Order Fulfillment & Flow Optimization

• Map and re-engineer end-to-end order flows: receiving → putaway → picking → packing → shipping for both web and store replenishment orders
• Analyze order profiles (unit count, SKU mix, order size, wave patterns) to optimize slotting, pick paths, and batch/zone strategies
• Design and refine conveyor, sortation, and packing line layouts to maximize throughput and minimize touches
• Partner with WMS/WCS teams to configure system rules, labor management, and directed work logic

Labor & Productivity

• Develop engineered labor standards (ELS) and time studies for all FC roles (pick, pack, receive, ship)
• Build staffing models aligned to volume forecasts, SLA targets, and peak planning (holiday, Prime-style events)
• Identify productivity gaps via LMS data and drive targeted improvement projects
• Support ergonomic assessments and workstation redesign to reduce injury rates

Continuous Improvement & Projects

• Lead Kaizen events, DMAIC projects, and rapid improvement workshops across all FC departments
• Reduce defects: mispicks, mis-ships, packaging damage, and returns driven by FC errors
• Own capital project lifecycle — business case, layout design, vendor selection, installation, and go-live
• Evaluate and pilot automation technologies: AMRs, goods-to-person systems, print-and-apply, automated packing

Data, Reporting & Compliance

• Build and maintain FC dashboards: units per hour (UPH), dock-to-stock time, order cut-off compliance, ship-on-time rate
• Develop SOPs, job aids, and training materials for new processes and equipment
• Ensure OSHA compliance and champion safety observation programs on the floor
• Coordinate with retail and e-commerce demand planning teams on volume forecasts and capacity planning
  

Requirements:

• B.S. in Industrial, Mechanical, Systems, or Supply Chain Engineering.
• 2–5 years in fulfillment, distribution, or logistics engineering. E-commerce or omnichannel Distribution Center experience strongly preferred.
• Bilingual in English and Spanish is required.
• WMS (Manhattan, Blue Yonder, SAP EWM), LMS, AutoCAD/SketchUp for layouts, Excel/SQL/Power BI, Minitab or similar.
• Six Sigma Green/Black Belt, Lean certification, or APICS CSCP/CLTD a plus. PMP helpful for capital project roles.