Lead Manufacturing Engineer, Material Flow

About Mach Industries Founded in 2023, Mach Industries is a rapidly growing defense technology company focused on developing next-generation autonomous defense platforms. At the core of our mission is the commitment to delivering scalable, decentralized defense systems that enhance the strategic capabilities of the United States and its allies. With a workforce of approximately 350 employees, we operate with startup agility and ambition. Our vision is to redefine the future of warfare through cutting-edge manufacturing, innovation at speed, and unwavering focus on national security. We are dedicated to solving the next generation of warfare with lethal systems that deter kinetic conflict and protect global security. The Role Mach Industries is seeking a Lead Material Flow Engineer to develop our internal logistics network to support consistent, on-time delivery of raw materials and WIP enabling high-rate production across Mach’s factories In this role, you will design and scale end-to-end material flow across multiple product lines and manufacturing sites. This role leads the development of safe, efficient, and traceable processes that move parts and assemblies from suppliers and warehouses to production points of use. Working with Supply Chain, Manufacturing, Production Control, Quality, Engineering, Facilities, and site leadership, you will prepare for next year's production ramp, deliver site-ready solutions, and establish standards that can be deployed consistently across Mach’s enterprise. Key Responsibilities Lead material-flow strategy and implementation for production growth across multiple product lines and sites, from concept and capacity planning through launch, stabilization, and handoff of a fully detailed production plan to Operations. Map current and future-state value streams, and build discrete event simulation models to test flow, routing, staging, and capacity decisions before committing capital. Develop project plans, budgets, risk assessments, and readiness reviews; communicate status, decisions, and escalations to stakeholders and leadership. Coordinate with facilities, construction, and outside line builders, integrators, and equipment suppliers so their designs fit the overall site plan and material-flow requirements. Develop a plan for every part (PFEP) covering the full bill of materials for new products, rate increases, and site expansions, defining each part's storage location, packaging, replenishment method, and delivery route. Analyze and select the right presentation method for each part (kitting, sequencing, or line-side bulk replenishment such as kanban) based on part size, variety, usage rate, cost, space, labor, ergonomics, and quality risk, then plan the kit and sequence designs, build areas, staging, and delivery cadence. Design line-side milk-run routes, delivery frequencies, and schedules, and set line-side stock requirements for each part in hours of coverage, including min/max levels and reorder triggers, balancing delivery cost, route capacity, line-side space, and line-stoppage risk. Design and improve inbound receiving and unloading, warehousing, kitting, sequencing, batching, intermediate storage, line-side delivery, point-of-use storage, and returnable-packaging processes. Develop handling strategies for the full range of aerospace materials, including large structures, raw stock, shelf-life and temperature-controlled materials such as composites, hazardous materials, and ESD-sensitive electronics. Develop cost-effective packaging and part-presentation solutions for manual and automated handling that protect parts from damage, foreign object debris (FOD), and electrostatic discharge (ESD). Create detailed facility and line-side material-flow layouts with Manufacturing Engineering and Facilities that support throughput, space, labor, inventory, ergonomics, and production-readiness targets. Evaluate and implement material-handling equipment and automation where appropriate, such as …

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