Key Responsibilities and Required Skills for Manufacturing Material Handler

🎯 Role Definition

The Manufacturing Material Handler is responsible for the safe, accurate and timely movement, staging, and replenishment of materials and components across production, shipping, receiving, and storage areas. This role ensures uninterrupted production flow by executing inventory control, material staging, documentation, and equipment operation (forklift, pallet jack, RF scanner) while following safety protocols and continuous improvement practices. Ideal candidates are reliable, detail-oriented, and experienced with warehouse management systems (WMS), ERP interfaces, and manufacturing Kanban/just-in-time (JIT) workflows.

📈 Career Progression

Typical Career Path

Entry Point From:

Warehouse Associate / General Laborer
Shipping & Receiving Clerk
Forklift Operator

Advancement To:

Lead Material Handler / Team Lead
Inventory Control Specialist / Supervisor
Logistics Coordinator
Production Supervisor / Materials Planner

Lateral Moves:

Quality Inspector (incoming materials)
Maintenance Technician (material handling equipment)
Supply Chain / Procurement Assistant

Core Responsibilities

Primary Functions

Receive, unload and inspect inbound raw materials, components and subassemblies; verify packing lists against purchase orders and update ERP/WMS records to ensure accurate receipt and traceability.
Pick, stage and deliver materials to production lines and work cells on time using forklifts, electric pallet jacks, and tow tractors, following Kanban/JIT replenishment cards and production schedules to prevent downtime.
Execute cycle counts, bin-to-bin moves, and full physical inventory reconciliations; research and correct discrepancies, document findings, and coordinate adjustments with Inventory Control and Procurement teams.
Operate sit-down, stand-up and reach trucks, overhead cranes or order pickers safely and efficiently for loading, unloading and positioning inventory; maintain current certifications and adhere to OSHA and company safety standards.
Load finished goods for shipment and assist with packing, labeling and staging outbound orders per shipping documentation and carrier requirements, ensuring damage-free transport and on-time shipping.
Use RF barcode scanners and WMS/ERP systems (e.g., SAP, Oracle, NetSuite) to scan, record and track inventory movements, perform cycle count entries, and update lot, serial and expiration date information accurately.
Stage materials for kitting and sub-assembly teams; prepare and deliver kits with complete parts lists and documentation, improving first-time quality and production efficiency.
Perform dock-to-stock and stock-to-line transfers, ensuring material locations are accurate, pallets labeled, and storage areas maintained for optimal FIFO/LIFO rotation and traceability.
Inspect incoming and outgoing shipments for damage, missing items or nonconformance; initiate claims, quarantine procedures, and nonconforming material reports when required.
Maintain organization and cleanliness of warehouses, storage racks, floors and staging areas; enforce 5S principles and report hazards or equipment malfunctions promptly.
Coordinate with production planners and supervisors to prioritize urgent material requests and expedite critical components to minimize line stoppages and support schedule adherence.
Execute packaging, crating and palletization of manufactured parts to company and carrier standards, ensuring compliance with export/import requirements and hazardous materials regulations when applicable.
Handle hazardous and regulated materials safely following MSDS/SDS guidelines and company procedures; use required PPE and ensure proper labeling, segregation and disposal.
Assist in inbound and outbound documentation processing including bills of lading, packing slips, inspection certificates and customs paperwork to maintain audit-ready records.
Support vendor returns and reverse logistics activities, verifying returned material condition, processing RMA paperwork, and coordinating replacements or credits with Purchasing.
Perform minor equipment maintenance and daily pre-operational checks on forklifts and material handling equipment; escalate maintenance needs and keep accurate maintenance logs.
Implement continuous improvement suggestions and participate in kaizen or lean events to reduce material handling cycle time, minimize damage and optimize floor layout for flow.
Train and mentor new material handlers on safe operation of equipment, inventory procedures, WMS transactions, and company policies to build a capable, cross-trained team.
Monitor inventory shelf life and expiration dates; rotate stock, mark obsolete items, and coordinate disposition or rework with Quality and Inventory Control.
Assist Quality and Engineering with material traceability, lot/serial tracking during product investigations, and maintain chain-of-custody records for audits and regulatory compliance.
Support production changeovers by staging required parts, removing finished product, and assisting line crews to ensure quick, safe transitions between production runs.
Prepare and maintain accurate, up-to-date records of material movements, discrepancies, damages and safety incidents for daily and weekly reporting to operations leadership.
Participate in emergency response plans (e.g., spill response, fire watches) and follow evacuation and lockout/tagout procedures as necessary.

Secondary Functions

Assist in developing standard operating procedures (SOPs) for material handling, receiving, and inventory control; document best practices and update training materials.
Support continuous improvement projects by gathering handling time data, suggesting layout changes, and testing new storage or picking methods.
Provide ad-hoc support for demand planning and purchasing by communicating low-stock situations, lead-time issues, and usage trends to planners.
Collaborate with cross-functional teams (Production, Quality, Safety, Purchasing) to solve material flow challenges and implement corrective actions.
Help maintain and validate BOM (bill of materials) accuracy with production and engineering to prevent pick errors and reduce scrap.
Participate in supplier audits and inspection activities by assisting with material verification, labeling and documentation as requested.

Required Skills & Competencies

Hard Skills (Technical)

Certified forklift operation (sit-down, stand-up, reach truck, order picker) with demonstrated safe operation experience.
Proficient with RF barcode scanners and handheld devices for pick/putaway and cycle count transactions.
Experience using WMS and ERP systems (examples: SAP, Oracle, NetSuite, Manhattan, Fishbowl) to record receipts, moves and shipments.
Strong inventory control skills: cycle counts, variance investigation, lot & serial tracking, FIFO/LIFO, shelf-life management.
Ability to read and interpret packing lists, bills of lading, work orders, BOMs and manufacturing drawings.
Knowledge of lean manufacturing principles (Kanban, JIT, 5S) and their application to material flow and staging.
Basic computer skills: Microsoft Excel for count reconciliation, simple formulas, and reporting.
Familiarity with hazardous materials handling and applicable regulatory labeling/segregation (SDS/MSDS).
Competence in packaging, palletization, shrink-wrapping and preparing shipments to carrier specifications.
Basic mechanical aptitude for minor equipment checks, preventative maintenance tasks and use of hand tools.

Soft Skills

Strong attention to detail with a focus on accuracy in inventory records and document control.
Excellent time management and ability to prioritize tasks in a fast-paced production environment.
Clear verbal communication and teamwork skills to coordinate with production, quality and logistics teams.
Problem-solving orientation to quickly resolve material discrepancies and line stoppages.
Reliable attendance, high energy and physical stamina for repeated lifting, walking and standing.
Safety-first mindset with commitment to follow and promote PPE, lockout/tagout and site safety rules.
Adaptability to changing production schedules, emergency material requests and continuous improvement initiatives.
Customer-service orientation toward internal stakeholders (production teams, planners, supervisors).
Instructional ability to train and mentor new hires on procedures and equipment operation.
Accountability and ownership for assigned tasks, inventory accuracy and safety compliance.

Education & Experience

Educational Background

Minimum Education:

High school diploma or equivalent (GED).

Preferred Education:

Technical certificate in Material Handling, Logistics, Warehouse Operations or Forklift Operator Certification.
OSHA safety training or equivalent manufacturing safety coursework.

Relevant Fields of Study:

Logistics, Supply Chain Management
Industrial Technology / Manufacturing Operations
Business Administration (operations focus)
Vocational training in material handling or equipment operation

Experience Requirements

Typical Experience Range: 0–5 years (entry-level to experienced roles)

Preferred:

1–3 years of hands-on experience in a manufacturing or warehouse environment supporting production.
Proven experience operating forklifts and material handling equipment with valid certifications.
Experience with WMS/ERP systems, RF scanning, and cycle count processes.
Prior exposure to lean manufacturing practices, Kanban systems, or production line support.
Demonstrated track record of safe work practices, reliable attendance, and teamwork.