Industrial Engineer (Packaging) - Contract Tier 1 Automotive Supplier

IAC Arlington is seeking an Industrial / Packaging Engineer to support upcoming program launches and facility preparation activities. This role will be added ahead of future launch milestones, allowing current Manufacturing and Industrial Engineering resources to remain focused on launch execution and production readiness activities.

The Industrial / Packaging Engineer will play a critical role in developing production layouts, optimizing material flow, validating work-in-process (WIP) and finished goods packaging systems, and ensuring operational readiness prior to Start of Production (SOP) and T1-2 launch milestones.

• Develop and maintain manufacturing layouts for new and existing programs.
• Optimize production flow from receiving through shipping.
• Evaluate space utilization and storage requirements.
• Support capital equipment placement and facility planning.

• Design efficient material presentation strategies.
• Develop and validate line-side delivery concepts.
• Improve warehouse and supermarket layouts.
• Support tugger routes and material replenishment systems.

• Lead development and validation of:
• WIP racks
• Finished goods racks
• Returnable packaging
• Shipping containers
• Coordinate packaging trials with suppliers and customers.
• Validate part presentation, ergonomics, and transportation requirements.
• Ensure compliance with GM packaging specifications.

• Support T1-2 launch preparation activities.
• Conduct packaging trials and transportation simulations.
• Validate rack densities and storage capacities.
• Coordinate launch readiness reviews.
• Support Run-at-Rate and production preparation activities.

• Perform:
• Time studies
• Capacity analysis
• Labor studies
• Process flow analysis
• Value stream mapping
• Support line balancing and labor optimization activities.
• Develop standard work documentation.

• Ensure manufacturing process designs and facility layouts comply with applicable safety regulations, customer requirements, and industry standards.
• Partner with the Environmental Health & Safety (EH&S) team to establish and maintain accident prevention programs and safety initiatives.
• Identify potential workplace hazards and recommend corrective actions to improve employee safety and ergonomic conditions.
• Support compliance with company safety policies and promote a culture of continuous safety improvement.

• Collaborate with Production and EH&S teams to develop and coordinate training programs related to manufacturing processes, safety practices, and operational procedures.
• Assist in the implementation of new processes, equipment, and manufacturing technologies by providing employee training and support.
• Promote best practices and standardized work methods throughout the organization.

• Work closely with:
• Manufacturing Engineering
• Supply Chain
• Production
• Quality
• Program Management
• Customer Packaging Engineering teams
• Participate in new product launches, process validation activities, and engineering change implementation.
• Support problem-solving activities and root cause analysis related to manufacturing performance, quality concerns, and process inefficiencies.
• Assist with APQP, PFMEA, Control Plans, and continuous improvement projects as required.

• Bachelor's Degree in Industrial Engineering, Manufacturing Engineering, Mechanical Engineering, or a related engineering discipline required.
• Minimum of 3 years of experience in industrial engineering, manufacturing engineering, or process improvement within a manufacturing environment.
• Experience in automotive manufacturing, preferably within a Tier 1 supplier environment.
• Experience conducting labor studies, capacity analysis, facility layout planning, and process optimization initiatives.
• Demonstrated experience in manufacturing process improvement and cost-reduction projects.

• Experience with Lean Manufacturing, Six Sigma, Kaizen, and other continuous improvement methodologies.
• Knowledge of automotive quality systems and core tools, including APQP, PPAP, PFMEA, MSA, and Control Plans.
• Strong knowledge of facility layout design, material flow analysis, ergonomics, and capacity planning.
• Experience developing performance metrics and analyzing manufacturing data to drive operational improvements.
• Familiarity with automation, robotics, PLC-controlled equipment, and modern manufacturing technologies.
• Strong analytical, project management, and problem-solving skills.
• Proficiency in Microsoft Office applications and manufacturing-related software.
• Excellent communication skills with the ability to collaborate effectively across all levels of the organization.

• Ability to work in a manufacturing environment with regular exposure to production equipment, noise, and varying temperatures.
• Ability to stand, walk, bend, climb, and move throughout the facility for extended periods.
• Ability to occasionally lift and carry up to 25 pounds.
• Ability to perform detailed observations, workflow studies, and ergonomic evaluations on the production floor.
• Ability to wear required personal protective equipment (PPE) and comply with all company safety requirements.
• Ability to travel between production areas and attend meetings, training sessions, and project activities as needed.