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Key Responsibilities and Required Skills for Warehouse Solutions Engineer

💰 $ - $

🎯 Role Definition

The Warehouse Solutions Engineer is a subject-matter expert who designs, implements, and validates warehouse management and automation solutions that improve throughput, accuracy, and cost-efficiency across distribution centers and manufacturing logistics operations. This role blends systems engineering, controls integration, business analysis, and project delivery to translate client requirements into pragmatic WMS/WES/automation implementations, supporting everything from site surveys and proof-of-concepts to commissioning, go-live and continuous improvement.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Warehouse Systems Analyst / WMS Analyst transitioning to engineering-focused delivery.
  • Controls or Automation Engineer with hands-on conveyor/PLC experience.
  • Implementation Consultant or Project Engineer from logistics or supply chain software vendors.

Advancement To:

  • Senior Solutions Engineer / Lead Solutions Architect (Warehouse Automation).
  • Solutions Architect — Supply Chain & Logistics Automation.
  • Program Manager or Director of Warehouse Automation / Distribution Technology.

Lateral Moves:

  • Implementation Consultant (WMS/WES/ERP integrations).
  • Supply Chain Solutions Consultant or Technical Account Manager.
  • Controls/PLC Engineer in industrial automation teams.

Core Responsibilities

Primary Functions

  • Lead discovery workshops with operations, supply chain, IT and business stakeholders to capture current-state workflows, pain points, throughput requirements, SKU profiles, and desired future-state outcomes to define a clear scope for WMS/WES and automation projects.
  • Architect end-to-end warehouse solutions that combine WMS/WES software, conveyors, sortation, pick-to-light, automated palletizers, AS/RS, AMRs/AGVs, RFID, and PLC-based controls to meet throughput, accuracy, and safety targets while minimizing total cost of ownership.
  • Create detailed functional and technical requirement documents, use cases, sequence diagrams, and acceptance criteria that translate business requirements into developer/controls deliverables and testable success metrics.
  • Lead vendor selection, procurement support and technical evaluations by developing RFP/RFI requirements, scoring matrices, and conducting proof-of-concept testing with WMS, WES, robotics, and material handling suppliers.
  • Design and manage system integrations between WMS/WES and host systems such as ERP (SAP, Oracle, NetSuite), TMS, MES, third-party logistics platforms, and real-time device controllers using APIs, middleware, and messaging standards (MQ, REST, SOAP).
  • Configure and customize WMS/WES application modules (inbound, putaway, replenishment, picking, packing, shipping, returns) to align system behavior with client operational processes and performance KPIs.
  • Develop and review PLC logic, I/O mappings, control sequences and HMI screens in collaboration with controls engineers to ensure deterministic integration between software directives and physical automation equipment.
  • Author detailed interface specifications, data models, and mapping documents for master data synchronization (item, location, pallet, lot/serial, UOM) and transactional messaging across systems.
  • Build test plans and lead functional, integration, system, performance and user-acceptance testing efforts in staging and pre-production environments, coordinating cross-discipline test teams and remediating defects.
  • Plan and execute factory acceptance tests (FAT) and site acceptance tests (SAT), including staging hardware/software, test scripts, throughput validation, and sign-off with client and vendor representatives.
  • Lead on-site commissioning and go-live activities: supervise cutover sequencing, hypercare support, monitor KPIs (cycle time, order lines per hour, accuracy), and apply rapid root-cause fixes to stabilize operations.
  • Create and deliver technical and end-user training materials, runbooks, and standard operating procedures for warehouse operations, maintenance teams and IT support to ensure knowledge transfer and operational readiness.
  • Perform capacity modeling, simulation and throughput analysis using discrete-event simulation or capacity-planning tools to justify automation investments and design trade-offs.
  • Conduct site surveys and readiness assessments to evaluate power, networking, floor space, racking, structural requirements, and environmental conditions and produce gap remediation plans.
  • Implement safety and compliance requirements into system designs, including lockout/tagout, safety PLC integration, E-stop circuits, light curtains, and integration with EHS processes.
  • Troubleshoot and resolve complex production incidents by analyzing logs, database records, PLC diagnostics and system traces; apply preventative fixes and update runbooks to prevent recurrence.
  • Collaborate with product management and engineering teams to define roadmap items, product enhancements and integrations that close capability gaps or support new automation technologies.
  • Provide ongoing operational support and continuous improvement consulting to reduce labor, optimize picking strategies (wave, batch, zone), and tune system rules for replenishment, slotting and cross-docking.
  • Drive cross-functional projects using Agile or hybrid project methodologies: facilitate sprint planning, manage backlog items for configuration and development, and ensure timely delivery of deliverables and milestones.
  • Maintain up-to-date technical documentation including architecture diagrams, network topologies, data flow diagrams, release notes, and configuration baselines to support maintainability and audits.
  • Partner with external vendors, third-party integrators, and internal procurement to manage deliveries, schedule installations, escalate technical issues, and ensure contractual SLAs are met.
  • Evaluate emerging warehouse technologies (vision systems, machine learning for slotting, robotics orchestration) and pilot PoCs to measure ROI and define adoption strategies for scale.

Secondary Functions

  • Support ad-hoc data requests and exploratory data analysis.
  • Contribute to the organization's data strategy and roadmap.
  • Collaborate with business units to translate data needs into engineering requirements.
  • Participate in sprint planning and agile ceremonies within the data engineering team.
  • Mentor junior engineers and coordinate knowledge transfer sessions to build internal capabilities.
  • Assist sales and presales teams by producing technical proposals, solution diagrams and scoping estimates for client opportunities.

Required Skills & Competencies

Hard Skills (Technical)

  • Deep knowledge of Warehouse Management Systems (WMS) and Warehouse Execution Systems (WES) — experience implementing or configuring major platforms such as Blue Yonder (JDA), Manhattan Associates, SAP EWM, Oracle WMS Cloud, or HighJump.
  • Strong experience integrating WMS/WES with ERP systems (SAP, Oracle), TMS, MES and third-party APIs using REST, SOAP, JSON, XML, and middleware platforms.
  • Hands-on experience with industrial controls and PLC programming (Siemens, Allen-Bradley/Rockwell), including ladder logic, function block programming, and I/O architectures.
  • Familiarity with robotics and AMR/AGV fleets, their orchestration platforms, and integration patterns for tasking, zone management and fleet telemetry.
  • Proficiency in SQL and ability to write complex queries for data validation, reporting, and troubleshooting; experience with relational databases like MS SQL Server, Oracle, or PostgreSQL.
  • Experience with message queuing and middleware (RabbitMQ, Kafka, IBM MQ) and near-real-time event-driven integration architectures.
  • Networking and infrastructure understanding for warehouse environments: VLANs, PoE for scanners, wireless AP planning (Wi-Fi), bandwidth considerations and edge computing requirements.
  • Experience designing and validating PLC-to-WMS/WES interfaces, including OPC-UA, MQTT, custom socket protocols, and deterministic control messaging.
  • Familiarity with scripting and automation languages (Python, PowerShell) for tooling, data migration, and test automation.
  • Experience with system commissioning, FAT/SAT processes, and operational handover procedures in material handling projects.
  • Ability to develop and analyze performance and throughput models, discrete-event simulation experience is a plus.
  • Knowledge of barcode/RFID technologies, mobile device management for handhelds/scan guns, and label printing protocols (ZPL, EPL).
  • Cloud and DevOps familiarity for deployment and monitoring of WMS/WES solutions (AWS/Azure, containerization, CI/CD pipelines) preferred.
  • Experience with safety systems integration (safety PLCs, E-stops, interlocks) and knowledge of OSHA/industry safety standards.

Soft Skills

  • Strong stakeholder management and communication skills—able to translate complex technical concepts to operations, business leaders, and procurement teams.
  • Problem-solving and analytical mindset with attention to detail and the ability to diagnose multi-layered system failures under production pressure.
  • Project management and organizational capabilities: time management, milestone tracking, risk mitigation and vendor coordination.
  • Collaborative team player with experience working in cross-functional, often distributed teams across engineering, operations, and product.
  • Customer-focused orientation with an ability to manage expectations and deliver high-quality, pragmatic solutions.
  • Adaptability and resilience in fast-paced deployment environments and willingness to travel for site commissioning and client engagements.
  • Coaching and mentorship skills for enabling junior staff and building internal knowledge.
  • Negotiation and conflict resolution skills to work with vendors and internal stakeholders to reach timely decisions.

Education & Experience

Educational Background

Minimum Education:

  • Bachelor's degree in Mechanical Engineering, Electrical Engineering, Industrial Engineering, Computer Science, Information Systems, Supply Chain Management, or a closely related technical discipline.

Preferred Education:

  • Master's degree in Systems Engineering, Supply Chain, Automation Engineering, or MBA with technical experience.
  • Relevant vendor certifications (e.g., Manhattan/Blue Yonder WMS, SAP EWM), controls certifications (Rockwell/Siemens), or project management (PMP, Scrum) are highly desirable.

Relevant Fields of Study:

  • Mechanical, Electrical or Industrial Engineering
  • Computer Science / Software Engineering
  • Supply Chain Management / Logistics
  • Automation & Controls Engineering

Experience Requirements

Typical Experience Range:

  • 3–8 years for mid-level roles; 5–12+ years for senior roles depending on complexity of automation and software landscape.

Preferred:

  • 5+ years implementing WMS/WES or integrated warehouse automation solutions with proven delivery of multiple end-to-end projects.
  • Demonstrable experience with PLC integration, system commissioning, FAT/SAT execution, and vendor/third-party management.
  • Experience in fast-moving consumer goods, e-commerce, third-party logistics (3PL), or manufacturing operations is a plus.
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