Material Handling Engineer (Ktp)

In this position...

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

We are the movers of the world and the makers of the future. We get up every day, roll up our sleeves and build a better world -- together. At Ford, we're all a part of something bigger than ourselves. Are you ready to change the way the world moves? As part of our Manufacturing team, you'll help build the world-class, state-of-the-art smart vehicles we're known for. In our plants around the world, we're constantly developing new technologies and processes to further increase our efficiency. You'll get the satisfaction of making great products people use and love.

What you'll do...

• 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 (line-side delivery, warehouse marketplace, kitting, 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 (Engineering, Purchasing, Suppliers, Operations) for all part, supplier, and process changes. Develop and execute change readiness plans (inventory burn-down, phase-in/phase-out, cutover timing, 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 (A3, 8D, DMAIC) to eliminate waste and variation
• Implement and support automation solutions (AGVs, AMRs, ASRS, 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 (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 (line disruption, premium freight, inventory write-offs, supplier readiness gaps)
• Enforce safety standards, ergonomics, and 5S discipline across all material handling operations. Manage resource planning (labor, equipment, space) 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 (APQP, PPAP impact to MP&L). Experience integrating automation with labor strategy (human-machine balance)
• Candidates must possess full flexibility and willingness to operate in a fast-paced, high-demand environment and a strong commitment to supporting team success during launches and critical business needs
• Provide engineering support for material flow process; document standards and procedures, provide training, overall adherence and maintenance to ensure materials are available in designated stock, markets and line locations throughout the facility.
• Work with Planning & Inventory Control, Production, Material Handlers, and Supply Chain to ensure robust policies are available and practiced and strive for continuous improvement.
• Apply technical expertise, commensurate with formal training and limited job experience, in the development of material flow processes.
• Design and/or develops material flow processes and equipment.
• Recommend changes to increase safety, reduce costs, improve quality and optimize efficiency.
• Participate in plant layout activities.
• Develop floor space analyses to confirm storage requirements and recommend practical solutions where required.
• Assist in qualifying manual and powered material handling equipment requirements
• Work to improve material flow and manage materials and inventory consistent with Lean principles.
• Lay out market, sequencing, and kitting areas to facilitate material handling, process flow, space utilization, and labor.
• Define and manages in-plant storage and call systems to maintain inventories; assists to define appropriate goals and metrics for proper material control.
• Provide vehicle and pedestrian flow/congestion/safety analyses and recommend practical solutions where required.
• Interact on a regular basis with other functional groups and vendors on technical and/or administrative matters.
• Work with Production, Material Handling, and Plant Safety Teams, Supply Chain, Quality, Material Logistics, Industrial Engineering, Ergonomic Engineering, Civil Engineering, Vehicle Manufacturing, Body Construction Engineering, and other engineering departments.
• Prepare detailed plans, generally spanning several months, vital to complete assigned projects.
• Develop and approves schedule milestones.
• Develop and coordinate labor, facility and equipment requirements for projects
• Propose alternate plans for economic evaluation.
• Administer technical procedures including process and work procedures.
• Implement industrial engineering systems and processes (forecast cost data, capacity, establish shop floor control systems, and ensure containment of material movement within floor space).
• Initiate all inbound packaging approval including efficiency cost savings projects to optimize packaging density.
• A key aspect of the role will be leading continuous improvement initiatives for returnable container packaging systems. This includes increasing pack density to optimize freight utilization, warehouse efficiency, and labor costs; reducing container and tooling costs through design optimization, standardization, and the adoption of emerging technologies; and enhancing part protection, functionality, durability, and overall packaging performance throughout the supply chain. The engineer will also support campaign and field activities related to container quality concerns, repair requirements, and performance issues. In addition, the position will play a critical role in advancing Packaging Engineering by researching, evaluating, and implementing innovative technologies, materials, processes, and best practices that improve operational efficiency and packaging effectiveness

What you'll do...

• 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 (line-side delivery, warehouse marketplace, kitting, 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 (Engineering, Purchasing, Suppliers, Operations) for all part, supplier, and process changes. Develop and execute change readiness plans (inventory burn-down, phase-in/phase-out, cutover timing, 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 (A3, 8D, DMAIC) to eliminate waste and variation
• Implement and support automation solutions (AGVs, AMRs, ASRS, 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 (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 (line disruption, premium freight, inventory write-offs, supplier readiness gaps)
• Enforce safety standards, ergonomics, and 5S discipline across all material handling operations. Manage resource planning (labor, equipment, space) 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 (APQP, PPAP impact to MP&L). Experience integrating automation with labor strategy (human-machine balance)
• Candidates must possess full flexibility and willingness to operate in a fast-paced, high-demand environment and a strong commitment to supporting team success during launches and critical business needs
• Provide engineering support for material flow process; document standards and procedures, provide training, overall adherence and maintenance to ensure materials are available in designated stock, markets and line locations throughout the facility.
• Work with Planning & Inventory Control, Production, Material Handlers, and Supply Chain to ensure robust policies are available and practiced and strive for continuous improvement.
• Apply technical expertise, commensurate with formal training and limited job experience, in the development of material flow processes.
• Design and/or develops material flow processes and equipment.
• Recommend changes to increase safety, reduce costs, improve quality and optimize efficiency.
• Participate in plant layout activities.
• Develop floor space analyses to confirm storage requirements and recommend practical solutions where required.
• Assist in qualifying manual and powered material handling equipment requirements
• Work to improve material flow and manage materials and inventory consistent with Lean principles.
• Lay out market, sequencing, and kitting areas to facilitate material handling, process flow, space utilization, and labor.
• Define and manages in-plant storage and call systems to maintain inventories; assists to define appropriate goals and metrics for proper material control.
• Provide vehicle and pedestrian flow/congestion/safety analyses and recommend practical solutions where required.
• Interact on a regular basis with other functional groups and vendors on technical and/or administrative matters.
• Work with Production, Material Handling, and Plant Safety Teams, Supply Chain, Quality, Material Logistics, Industrial Engineering, Ergonomic Engineering, Civil Engineering, Vehicle Manufacturing, Body Construction Engineering, and other engineering departments.
• Prepare detailed plans, generally spanning several months, vital to complete assigned projects.
• Develop and approves schedule milestones.
• Develop and coordinate labor, facility and equipment requirements for projects
• Propose alternate plans for economic evaluation.
• Administer technical procedures including process and work procedures.
• Implement industrial engineering systems and processes (forecast cost data, capacity, establish shop floor control systems, and ensure containment of material movement within floor space).
• Initiate all inbound packaging approval including efficiency cost savings projects to optimize packaging density.
• A key aspect of the role will be leading continuous improvement initiatives for returnable container packaging systems. This includes increasing pack density to optimize freight utilization, warehouse efficiency, and labor costs; reducing container and tooling costs through design optimization, standardization, and the adoption of emerging technologies; and enhancing part protection, functionality, durability, and overall packaging performance throughout the supply chain. The engineer will also support campaign and field activities related to container quality concerns, repair requirements, and performance issues. In addition, the position will play a critical role in advancing Packaging Engineering by researching, evaluating, and implementing innovative technologies, materials, processes, and best practices that improve operational efficiency and packaging effectiveness