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Key Responsibilities and Required Skills for Warehouse Process Engineer

💰 $ - $

LogisticsOperationsEngineeringSupply ChainContinuous Improvement

🎯 Role Definition

This role requires a results-driven Warehouse Process Engineer to lead process design, continuous improvement, and capacity planning initiatives across multi-site distribution operations. The ideal candidate blends industrial engineering fundamentals, hands-on warehouse operations experience, and data-driven problem solving to increase throughput, reduce operational cost, and improve safety, accuracy, and on-time fulfillment. This role partners with operations, supply chain, maintenance, automation vendors, and IT to define best-in-class warehouse processes, deploy Warehouse Management System (WMS) changes, and deliver measurable KPIs (OTIF, cycle time, order accuracy, cost per unit).

📈 Career Progression

Typical Career Path

Entry Point From:

  • Warehouse Supervisor or Operations Team Lead with strong process interest
  • Industrial / Manufacturing Engineer transitioning to distribution environment
  • Continuous Improvement / Kaizen Coordinator in logistics or manufacturing

Advancement To:

  • Senior Warehouse Process Engineer / Principal Process Engineer
  • Manager of Continuous Improvement or Process Engineering
  • Operations Director or Head of Distribution / Fulfillment Center

Lateral Moves:

  • Quality Engineer (Distribution Quality)
  • Supply Chain Planner or Network Optimization Analyst
  • Automation / Robotics Integration Engineer

Core Responsibilities

Primary Functions

  • Lead end-to-end process design and optimization projects to increase warehouse throughput, reduce touches per order, minimize travel time, and lower cost-per-order; deliver quantified results (e.g., % throughput gain, $ savings) and maintain project documentation for ROI tracking.
  • Conduct time and motion studies, standard work creation, and takt time calculations to establish baseline productivity and set achievable targets for picks, putaways, replenishment, packing, and shipping operations.
  • Design and implement slotting strategies, SKU velocity segmentation, and layout reconfigurations to optimize cube utilization, reduce travel distances, and improve order cycle time across static and dynamic slotting environments.
  • Lead warehouse capacity planning, labor modeling, and demand forecasting alignment using historical volume, seasonality, and promotions data to size teams, shifts, and equipment needs while minimizing overtime and agency spend.
  • Drive continuous improvement using Lean, Six Sigma, and Kaizen methodologies—lead DMAIC projects, value stream mapping workshops, root cause analysis, and cross-functional action plans to eliminate waste and variation.
  • Define, implement, and maintain operational KPIs and dashboards (OTIF, order accuracy, cycle time, units per hour, dock-to-stock time) and provide regular performance reporting and insights to site leadership and corporate stakeholders.
  • Serve as the technical lead for WMS (e.g., Blue Yonder, Manhattan, SAP EWM) configuration changes, including wave logic, replenishment rules, directed putaway/pick, and task interleaving; validate changes through simulation and controlled deployments.
  • Partner with IT and data teams to extract, validate, and analyze operational datasets using SQL, Excel, or scripting to identify trends, generate hypotheses, and quantify impact of process changes.
  • Design and validate new automation, material handling, robotics, and conveyor systems in collaboration with vendors—develop requirements, run FAT/SAT tests, and lead integration plans to ensure operational readiness.
  • Create and maintain process documentation, standard operating procedures (SOPs), training materials, and visual management tools to support consistent execution and quick onboarding of seasonal or permanent staff.
  • Manage pilot programs for new equipment, software features, or layout changes—define success metrics, conduct controlled A/B pilots, and scale solutions across multiple sites with change management plans.
  • Lead cross-functional problem solving during critical incidents (e.g., capacity overload, system downtime, inventory discrepancies) to restore service levels quickly while preventing recurrence through corrective actions.
  • Evaluate and recommend material handling equipment (forklifts, RF scanners, pick carts, sorters, palletizers) specifications and procurement priorities to align capital investments with operational ROI and safety standards.
  • Conduct regular process audits, safety risk assessments, and compliance checks—drive corrective actions and ensure conformance to regulatory and internal safety requirements.
  • Implement and optimize replenishment policies (min/max, batch sizes, Kanban) and slotting algorithms to reduce stockouts, lower picking travel, and improve replenishment efficiency across fast- and slow-moving SKUs.
  • Facilitate cross-training programs and competency matrices for operations to ensure flexible labor coverage and resilient operations during peak demand or reduced headcount scenarios.
  • Build business cases, cost-benefit analyses, and implementation timelines for infrastructure or process investments; secure stakeholder buy-in and track post-implementation benefits against targets.
  • Define and monitor quality checkpoints and error-proofing controls to improve order accuracy, packing quality, and reduce returns; partner with quality teams to analyze root causes and implement permanent fixes.
  • Maintain vendor and contractor relationships for automation, MHE maintenance, and system integrators—drive vendor performance, service level expectations, and resolution of technical issues.
  • Translate customer service and carrier requirements into operational process changes to improve on-time shipping, carrier compliance, and reduce chargebacks and penalties.
  • Mentor junior engineers and operations leaders on process engineering principles, data analysis techniques, and continuous improvement mindsets; create succession plans and skills development paths.
  • Prepare and present regular updates to senior leadership including status of improvement initiatives, risk registers, financial impact, and recommendations for scaling successful pilots.

Secondary Functions

  • Support ad-hoc data requests and exploratory analysis to help site leadership answer immediate operational questions and test hypotheses.
  • Contribute to the organization’s warehouse process strategy and roadmap, aligning local site plans with regional distribution strategy and network optimization goals.
  • Collaborate with business units (procurement, customer service, transportation) to translate operational needs into engineering requirements and WMS/ERP change requests.
  • Participate in sprint planning and agile ceremonies with IT and product teams when implementing WMS, automation, or analytics features to promote iterative delivery and rapid feedback.
  • Assist site HR and training teams in developing competency-based training modules, certification paths, and performance standards for process changes.
  • Help coordinate safety, compliance, and continuous improvement communications to front-line teams, including toolbox talks and visual performance boards.
  • Support inventory accuracy initiatives, cycle counting programs, and reconciliation workflows in partnership with inventory control teams.
  • Provide subject-matter expertise during facility expansions, relocations, or new site startups including layout planning, equipment spec, and ramp-up playbooks.
  • Help evaluate and adopt new analytics tools, simulation software, or dashboard platforms to improve timeliness and accuracy of operational insights.
  • Serve as escalation point for cross-site process consistency questions and share best practices across the network.

Required Skills & Competencies

Hard Skills (Technical)

  • Warehouse Management System (WMS) configuration and testing experience (e.g., Manhattan, Blue Yonder/JDA, SAP EWM, Oracle WMS) with proven ability to translate operational needs into system rules and logic.
  • Strong data analysis skills: SQL querying, advanced Excel (pivot tables, lookups, macros), and experience with BI tools (Tableau, Power BI, Looker) for KPI tracking and root cause analysis.
  • Industrial engineering fundamentals: time studies, standard work creation, line balancing, takt time, and throughput optimization.
  • Lean and Six Sigma methodologies with practical experience leading DMAIC projects; Green Belt or Black Belt certification preferred.
  • Slotting and space optimization expertise, including the use of slotting tools or algorithms and knowledge of cube utilization and weight/velocity profiling.
  • Material handling and automation knowledge: conveyors, sortation systems, AS/RS, robotics, palletizers, forklifts, and hands-on experience with vendor integration.
  • Labor modeling and workforce planning tools experience; ability to model staffing scenarios, shifts, and OT costs to meet service SLAs.
  • Process simulation and discrete event simulation familiarity (AnyLogic, FlexSim, Simio) to validate layout and throughput changes prior to deployment.
  • Basic scripting or programming skills (Python, R, or VBA) for automation of analyses and repeatable data tasks.
  • Experience with inventory control processes: cycle counting, discrepancy resolution, ownership, and reconciliation workflows.
  • Project management skills: scoping, scheduling, risk mitigation, resource coordination, and status reporting—PMP or equivalent experience preferred.
  • Understanding of safety regulations and ergonomics as applied to warehousing operations, including risk assessment and mitigation.
  • Experience with RFID/RF technology, barcode systems, and mobile scanning workflows for directed tasks.

Soft Skills

  • Exceptional analytical and problem-solving skills with the ability to translate data into pragmatic operational recommendations and measurable outcomes.
  • Strong communication skills—able to present technical concepts and ROI cases to both frontline teams and executive leadership.
  • Cross-functional collaboration and stakeholder management—builds consensus across operations, IT, procurement, and finance.
  • Change management and coaching—drives adoption of new processes through training, visualization, and reinforcement.
  • Project leadership and prioritization—manages multiple improvement initiatives concurrently while delivering results on time.
  • Attention to detail and process discipline—ensures SOPs, audits, and documentation are accurate and followed consistently.
  • Resilience and adaptability in fast-paced distribution environments with fluctuating demand and competing priorities.
  • Influencing and negotiation skills when working with external vendors and internal partners to secure resources and timeline commitments.
  • Time management and organizational skills to balance hands-on floor time with data analysis and stakeholder meetings.
  • Customer-focused mindset—translates customer and carrier requirements into tangible process improvements that enhance service levels.

Education & Experience

Educational Background

Minimum Education:

  • Bachelor’s degree in Industrial Engineering, Mechanical Engineering, Manufacturing Engineering, Supply Chain Management, Operations Management, or related technical discipline.

Preferred Education:

  • Master’s degree in Industrial Engineering, Operations Research, Supply Chain, or MBA with operations focus.
  • Lean / Six Sigma Green Belt or Black Belt certification.
  • Certifications in WMS administration, project management (PMP), or prevention-focused safety certifications are a plus.

Relevant Fields of Study:

  • Industrial Engineering
  • Supply Chain / Logistics
  • Mechanical Engineering
  • Operations Management
  • Systems Engineering

Experience Requirements

Typical Experience Range:

  • 3–8 years of combined engineering and warehouse/distribution operations experience.

Preferred:

  • 5+ years of hands-on warehouse process engineering experience in high-volume distribution centers or omni-channel fulfillment environments.
  • Demonstrated experience implementing WMS changes, leading automation integration, and delivering measurable productivity improvements (e.g., % improvement in throughput or cost savings).
  • Proven track record of leading cross-functional continuous improvement projects and scaling pilots across multiple sites.
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