Position Summary We are seeking an experienced engineer to lead the design, evaluation, implementation, commissioning, and optimization of automated material handling solutions across warehousing, fulfillment, distribution, and co-packing operations. Candidates with prior experience working for an MHS OEM or system integrator, particularly in conveyor, sortation, and integrated warehouse automation design and implementation, are strongly preferred. This role will serve as a technical lead for complex MHS projects involving conveyor systems, sortation, accumulation, merges, diverts, AS/RS, pallet handling, scanning and identification systems, controls, and warehouse software integration. The Senior Engineer will own projects through the full engineering lifecycle, from concept development and requirements definition through vendor selection, detailed design, FAT, installation, SAT, commissioning, performance validation, stabilization, and operational handoff. Work Location: Within commutable distance of Atlanta, GA or Chicago, IL Work Schedule: Monday-Friday, 8:00 AM-5:00 PM Eastern Time, with flexibility based on project and startup requirements Travel: Approximately 50-75% Key Responsibilities Material Handling Systems Engineering
- Lead the design, engineering, implementation, and optimization of Material Handling Systems (MHS) for warehouse, distribution, fulfillment, and co-packing operations.
- Develop system concepts incorporating belt and roller conveyor, MDR, accumulation conveyor, merges, diverts, sortation, pallet conveyor, palletizing/depalletizing, and automated storage technologies.
- Perform throughput, capacity, cycle-time, accumulation, queue, bottleneck, and system utilization analysis to validate proposed designs.
- Review and approve system layouts, elevations, equipment arrangements, conveyor routing, operator interfaces, maintenance access, guarding, and equipment clearances.
- Develop and review equipment specifications, functional requirements, Design/Description of Operations, control narratives, sequence of operations, and system performance requirements.
- Ensure designs appropriately address maintainability, reliability, ergonomics, operational accessibility, safety, and lifecycle cost. Controls & Systems Integration
- Provide technical oversight for PLC-controlled conveyor and material handling systems, including sensors, photo eyes, VFDs, motors, scanners, safety devices, control panels, and industrial networks.
- Review control architecture, equipment zoning, accumulation logic, merge logic, fault recovery, start/stop sequences, and E-stop functionality.
- Support integration between MHS equipment and WCS/WES/WMS/WES equivalent platforms, middleware, PLCs, scanners, vision systems, robotics, and other warehouse technologies.
- Review controls and integration documentation including I/O lists, network architecture, control narratives, and interface requirements.
- Lead technical troubleshooting of mechanical, controls, communication, and system integration issues during commissioning and stabilization. System Performance & Acceptance
- Define measurable system acceptance criteria for throughput, availability, reliability, scan/read rate, sort accuracy, tracking accuracy, cycle time, and equipment performance.
- Develop and execute FAT, SAT, UAT, high-volume testing, reliability testing, and performance acceptance plans.
- Validate system performance against contractual requirements and approved design criteria.
- Analyze downtime, faults, jams, recirculation, rejects, mis-sorts, no-reads, equipment utilization, and other performance data to identify root causes and improvement opportunities.
- Drive corrective actions with OEMs and system integrators until contractual and operational requirements are achieved.
- Support transition from project commissioning into operational stabilization and final acceptance. Project Engineering & Vendor Management
- Serve as the technical engineering lead for MHS projects from concept through final acceptance.
- Develop technical requirements, RFQs/RFPs, bid packages, equipment specifications, and scopes of work.
- Conduct technical bid evaluations and support vendor/integrator selection based on technical capability, performance, lifecycle cost, schedule, and risk.
- Review vendor drawings, submittals, calculations, controls documentation, equipment specifications, schedules, and change requests.
- Challenge vendor assumptions and identify design gaps, technical risks, scope conflicts, and performance concerns before implementation.
- Coordinate engineering activities across Operations, Industrial Engineering, IT, Maintenance, Safety, Procurement, Construction, customers, OEMs, and system integrators.
- Manage technical scope, schedule, risks, open issues, punch lists, and engineering changes throughout implementation.
- Provide on-site technical leadership during installation, commissioning, startup, and operational ramp-up. Technical Leadership
- Serve as a senior technical resource for material handling and warehouse automation projects.
- Lead design reviews and provide technical recommendations to engineering, operations, and business leadership.
- Establish and improve engineering standards, specifications, acceptance criteria, and best practices for MHS projects.
- Mentor junior engineers and support development of internal MHS and automation engineering capabilities.
- Evaluate emerging technologies and determine their technical and operational applicability.
- Translate operational requirements into practical, scalable, and maintainable engineering solutions. Minimum Qualifications
- Bachelor’s degree in Mechanical Engineering, Electrical Engineering, Industrial Engineering, Mechatronics, Automation Engineering, or a related technical discipline.
- 7+ years of relevant engineering experience in material handling, warehouse automation, distribution, fulfillment, manufacturing automation, or system integration.
- Demonstrated experience designing, implementing, commissioning, or supporting conveyor and automated material handling systems.
- Strong understanding of conveyor technologies, accumulation, merges, diverts, sortation, material flow, equipment capacity, and throughput analysis.
- Experience managing projects through design, procurement, installation, commissioning, FAT/SAT, performance testing, and operational handoff.
- Working knowledge of PLC controlled industrial equipment, sensors, motors, VFDs, industrial networks, and safety systems.
- Ability to read and review mechanical layouts, elevations, electrical drawings, controls documentation, and equipment specifications.
- Strong troubleshooting and root cause analysis capabilities across mechanical, electrical, controls, and integration disciplines.
- Experience working directly with OEMs, system integrators, contractors, and operational stakeholders.
- Strong technical communication skills with the ability to present engineering recommendations and risks to both technical and nontechnical stakeholders.
- Ability to travel approximately 50-75%, including extended site presence during critical installation, commissioning, and startup periods. Preferred Qualifications
- Prior experience working for a Material Handling Systems (MHS) OEM, conveyor manufacturer, or system integrator is strongly preferred.
- 5+ years of experience designing, engineering, integrating, commissioning, or supporting automated material handling systems.
- Hands-on engineering experience with conveyor systems, MDR, accumulation, merges, diverts, sortation, pallet handling, AS/RS, scanning systems, AMRs/AGVs, and robotic applications.
- Experience developing MHS solutions from concept and proposal through detailed engineering, installation, commissioning, SAT, performance testing, and customer acceptance.
- Experience performing system sizing, throughput calculations, conveyor capacity analysis, accumulation analysis, equipment selection, and material flow analysis.
- Experience developing or reviewing AutoCAD layouts, conveyor elevations, equipment specifications, controls narratives, sequence/Description of Operations, I/O requirements, and system architecture.
- Experience working directly with customers to translate operational requirements into technical MHS designs and performance requirements.
- Experience supporting RFQ/RFP responses, estimating, technical proposals, scope development, and equipment/vendor selection.
- Strong understanding of the relationship between mechanical design, controls, PLC logic, WCS/WES integration, scanning, and overall system performance.
- Experience troubleshooting MHS performance issues including jams, tracking failures, accumulation issues, merge congestion, recirculation, no-reads, mis-sorts, and throughput constraints.
- Experience conducting or supporting FAT, SAT, UAT, high-volume testing, reliability testing, and final system acceptance.
- Knowledge of applicable CEMA, OSHA, ANSI, NFPA, and machinery/conveyor safety requirements.
- Experience with high throughput 3PL, e-commerce, retail distribution, fulfillment, manufacturing, or co-packing environments. This position is not eligible for immigration sponsorship. Full posting: https://www.linkedin.com/jobs/view/sr-robotics-and-automation-engineer-at-confidential-4470324301
