Industrial Engineer I

Job Purpose The Industrial Engineer I is responsible for analyzing, developing, designing, and implementing solutions that improve productivity, labor utilization, storage capacity, material flow, ergonomics, quality, safety, and operational efficiency across Parts Distribution Center operations. This position applies industrial engineering and Lean methodologies, including manpower analysis, takt-time and cycle-time studies, process standardization, layout optimization, root-cause analysis, and continuous improvement techniques. The role also supports the safe handling and storage of EV and HEV batteries and the design of purpose-built material-handling tools, carts, bins, containers, fixtures, and storage solutions. The position supports projects from initial problem identification and concept development through design, implementation, validation, and post-implementation review. Key Accountabilities Industrial Engineering and Operational Analysis Conduct time studies, takt-time studies, cycle-time analysis, workload analyses, and manpower evaluations.Analyze productivity, labor utilization, operational capacity, material flow, ergonomics, and process performance.Identify process bottlenecks, waste, capacity constraints, safety risks, ergonomic concerns, and improvement opportunities.Develop labor standards, operating standards, and productivity expectations based on verified operational data.Evaluate processes, systems, layouts, equipment, and failure modes to identify practical solutions.Perform root-cause analysis and support corrective actions for operational, design, safety, and implementation issues. Warehouse Layout, Storage, and Material Flow Develop and evaluate warehouse layouts, storage concepts, work areas, and material-flow solutions.Optimize product placement, storage utilization, aisle configuration, staging areas, process flow, and warehouse space.Support capacity planning and determine current and future space, storage, equipment, and labor requirements.Evaluate storage methods, bins, containers, racks, carts, and material-handling solutions to improve accessibility, ergonomics, productivity, product protection, and space utilization.Develop storage and staging concepts for EV and HEV batteries based on battery type, size, weight, packaging, condition, handling method, and operational risk.Prepare layouts, calculations, specifications, and project recommendations using applicable engineering tools.Ensure layouts, storage systems, equipment, and work processes align with Lean principles, safety expectations, operational requirements, and applicable standards. EV and HEV Battery Handling, Storage, and Safety Support the development, implementation, and continuous improvement of safe, scalable EV and HEV battery receiving, inspection, staging, storage, picking, charging, transportation, quarantine, and disposal processes.Evaluate battery-related hazards and operational risks, including high voltage, electrical shock, arc flash, electrolyte exposure, damaged batteries, off-gassing, fire, and thermal runaway.Partner with Safety, Operations, Facilities, Quality, and other stakeholders to develop risk assessments, engineering controls, storage requirements, SOPs, work instructions, training materials, and emergency-response practices.Support the selection and implementation of battery storage systems, handling equipment, containment solutions, monitoring devices, PPE, signage, visual controls, and emergency equipment.Confirm proposed battery-handling and storage solutions align with applicable regulatory requirements, OEM instructions, site requirements, and recognized industry practices.Support site assessments, readiness reviews, compliance audits, drills, corrective actions, and standardization across PDC operations. Ergonomic Tool and Material-Handling Solution Design Design, develop, prototype, test, and improve material-handling carts, dollies, racks, fixtures, workstations, bins, totes, storage containers, pick devices, transport devices, and other custom tools.Translate product dimensions, weights, center of gravity, handling risks, throughput, storage requirements, and operator needs into practical design criteria.Apply ergonomic and human-factors principles to reduce lifting, reaching, bending, pushing, pulling, repetitive motion, awkward posture, and product-handling risk.Develop solutions that improve process flow, picking efficiency, storage density, accessibility, inventory control, quality, and employee safety.Create and review concepts, CAD drawings, specifications, load requirements, prototypes, test plans, and validation criteria for custom equipment.Coordinate fabrication and implementation with users, suppliers, contractors, Safety, Quality, and Facilities, and incorporate operator feedback and lessons learned into final designs. Continuous Improvement Lead or support continuous improvement projects using Lean principles and structured problem-solving methods.Plan and facilitate Kaizen activities to improve productivity, quality, safety, ergonomics, space utilization, and operational flow.Identify and eliminate waste and non-value-added activities while standardizing best practices.Apply lessons learned and post-implementation findings to future designs and processes.Support a culture of continuous improvement and benchmark relevant best practices. Equipment and Solution Development Identify and evaluate equipment, storage systems, material-handling solutions, battery-safety equipment, and process technologies.Develop technical requirements, scopes of work, design criteria, ergonomic requirements, and performance or validation specifications.Review vendor proposals, calculations, drawings, prototypes, and technical submissions for alignment with operational, safety, and project requirements.Perform cost-benefit and return-on-investment analyses for proposed improvements.Coordinate with internal teams, suppliers, contractors, and external resources during development and implementation.Validate implemented solutions against approved requirements, safe working loads, ergonomic objectives, and expected performance. Project Management Manage assigned engineering and continuous improvement projects from initiation through implementation and closeout.Develop project plans identifying scope, milestones, deliverables, responsibilities, timelines, risks, and open issues.Monitor progress and escalate schedule, cost, quality, safety, or technical concerns when necessary.Coordinate activities with Operations, Safety, Quality, IT, Facilities, Purchasing, suppliers, contractors, and other stakeholders.Lead or participate in project status meetings and communicate progress to appropriate levels of the organization.Support implementation, startup, training, performance validation, and post-project reviews. Data Analysis, Reporting, and Documentation Collect, validate, organize, and analyze operational, ergonomic, safety, and project data.Identify incomplete or inaccurate data and obtain clarification or verification.Develop reports, dashboards, analyses, and presentations that support decision-making.Provide weekly reporting on productivity, manpower planning, labor utilization, and assigned project status.Support monthly reporting related to standards, specifications, operational improvements, safety, and waste reduction.Create and maintain calculations, layouts, CAD drawings, reports, project records, design standards, specifications, SOPs, work instructions, risk assessments, and validation documentation. Key Performance Indicators Productivity improvement and labor utilization.Storage and space utilization.Ergonomic risk reduction and improvement of material-handling methods.Safe and compliant EV and HEV battery handling and storage practices.Reduction of process waste, product damage, and non-value-added activity.Completion of assigned projects within approved scope and schedule.Quality and accuracy of engineering analyses, designs, and deliverables.Implementation and sustainability of process, equipment, storage, and safety improvements.Timeliness and accuracy of operational and project reporting.Completion and maintenance of standards, specifications, SOPs, and work instructions.Achievement of validated project benefits and expected returns. Work Schedule and Travel Requirements Work Schedule: Monday-Friday, 8:00 AM - 5:00 PM; flexible schedule at the discretion and approval of the manager.Travel Required: Yes.Travel Details: Occasional overnight travel (up to 30%) by land and/or air