Industrial Engineer, Logistics & Material Flow

About the job

Why Castelion, Why Now

Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus, ownership, and excellence are decisive advantages - and we're building a world-class team to turn bold ideas into real capability.

This is a rare opportunity to join at an early stage, where you'll have significant ownership, collaborate with exceptional teammates, and make a direct, measurable impact on our mission and the future of the company - regardless of your function.

Industrial Engineer, Logistics & Material Flow

Castelion is seeking a highly skilled Industrial Engineer to design and scale the logistics systems that support our manufacturing operations. You will own the systems-level view of warehouse layouts, material flow, internal routing, packaging, transportation, and multisite logistics.

This role sits at the intersection of industrial engineering, supply chain, manufacturing, and program execution. You will translate production requirements, inventory data, facility constraints, and transportation needs into practical systems that ensure materials arrive at the right place, at the right time, in the right condition.

You will help build the infrastructure required to scale from prototype and low-rate production into high-rate manufacturing across multiple facilities, suppliers, test sites, and external partners.

Responsibilities

• Design and optimize warehouse, stockroom, staging, kitting, shipping, receiving, and material-handling layouts to maximize space utilization, safety, inventory accuracy, and throughput.

• Develop and maintain end-to-end material-flow maps covering suppliers, receiving, inspection, storage, point-of-use delivery, production, finished goods, shipping, and external sites.

• Define internal routing strategies, milk runs, tugger routes, delivery frequencies, supermarket locations, point-of-use replenishment, and material presentation standards.

• Analyze demand, production schedules, inventory levels, shipment history, and facility constraints to model warehouse and logistics capacity.

• Develop multisite transportation plans supporting the movement of materials, tooling, production hardware, equipment, and finished goods between facilities, suppliers, test sites, and customers.

• Build transportation models that evaluate route frequency, shipment consolidation, vehicle and trailer requirements, carrier performance, lead times, cost, and service-level risk.

• Develop packaging, labeling, containerization, and material-protection requirements for components, hardware, tooling, hazardous materials, and mission-critical equipment.

• Partner with quality, manufacturing, supply chain, and engineering teams to establish packaging standards that protect hardware from damage, contamination, corrosion, electrostatic discharge, and environmental exposure.

• Define reusable container strategies, dunnage, racks, pallets, carts, returnable packaging, and other material-handling equipment.

• Conduct time studies, travel-path analyses, warehouse slotting studies, labor standards, and process observations to identify bottlenecks and eliminate non-value-added work.

• Create and maintain process flow diagrams, spaghetti diagrams, value-stream maps, warehouse layouts, routing guides, and standard work.

• Establish inventory-storage policies, location strategies, FIFO/FEFO requirements, quarantine areas, secure storage, hazardous-material segregation, and controlled-access zones.

• Develop operating standards for receiving, put-away, picking, kitting, staging, loading, shipping, returns, and intersite transfers.

• Build and maintain logistics performance metrics, including inventory accuracy, dock-to-stock time, pick accuracy, order cycle time, space utilization, transportation cost, on-time delivery, damage rates, and material availability.

• Use data to lead root-cause investigations into shortages, late deliveries, excess handling, damaged hardware, routing inefficiencies, and warehouse capacity constraints.

• Support warehouse management system, ERP, barcode, RFID, and material-tracking process improvements.

• Partner with software, operations, and supply chain teams to define system requirements, master data, transactions, location structures, and reporting needs.

• Support facility planning, equipment selection, automation assessments, and capital-investment decisions with data-driven capacity and cost models.

• Lead capacity studies and risk assessments for new facilities, warehouse expansions, production ramps, and multisite operating models.

• Establish contingency plans for transportation disruptions, supplier delays, facility outages, vehicle constraints, and other logistics risks.

• Develop and maintain standard work, operating procedures, routing guides, packaging instructions, and training materials.

• Coordinate with suppliers, carriers, brokers, and external logistics partners to improve service, cost, reliability, and compliance.

• Work cross-functionally with manufacturing, supply chain, procurement, quality, finance, facilities, security, and program management to align logistics plans with production schedules, cost targets, and delivery objectives.

• Travel between company facilities, suppliers, logistics partners, and test sites as required to implement and improve logistics systems.

Basic Qualifications

• Bachelor's degree in industrial engineering, supply chain, logistics, manufacturing, mechanical, systems engineering, or a related field.

• 3+ years of experience in industrial engineering, warehouse engineering, logistics engineering, manufacturing, distribution, or a related operating environment.

• Experience designing or improving warehouse layouts, material-flow systems, transportation processes, or inventory operations.

• Experience analyzing operational data and developing capacity, labor, space, routing, or cost models.

• Ability to create process maps, layouts, standard work, and operational documentation.

• Strong analytical, problem-solving, and communication skills.

• Ability to work effectively in a fast-paced, changing environment and manage multiple priorities.

• Ability to work hands-on in warehouse, manufacturing, and logistics environments.

Preferred Skills and Experience

• Experience supporting hardware development, aerospace, defense, automotive, electronics, or other complex manufacturing environments.

• Experience transitioning operations from prototype or low-rate production to high-rate production.

• Experience designing multisite logistics networks, interfacility transportation plans, or regional distribution models.

• Experience with warehouse slotting, pick-path optimization, kitting, supermarkets, kanban, milk runs, or point-of-use delivery.

• Experience with packaging engineering, returnable containers, dunnage, crating, shock and vibration protection, ESD controls, or sensitive-hardware handling.

• Familiarity with transportation planning, carrier management, freight classification, shipment consolidation, routing guides, and delivery-service metrics.

• Experience with warehouse management systems, ERP systems, barcode/RFID technologies, or inventory-control systems.

• Experience with CAD, Visio, AutoCAD, SketchUp, or similar tools for developing warehouse and facility layouts.

• Comfort building dashboards or lightweight data pipelines using Excel, SQL, Python, Tableau, Power BI, or similar tools.

• Experience with discrete-event simulation, facility modeling, network optimization, or logistics modeling tools.

• Background in lean manufacturing, Six Sigma, Kaizen, 5S, Theory of Constraints, or other continuous-improvement methodologies.

• Experience developing labor standards, conducting time studies, and performing ergonomic or travel-distance analyses.

• Familiarity with APQP, Control Plans, PFMEA, process risk assessments, and managing significant or critical characteristics.

• Experience with hazardous-material transportation, DOT requirements, export-controlled hardware, or secure logistics is a plus.

• Familiarity with Atlassian tools such as Confluence and JIRA.

• Forklift, powered industrial truck, or other material-handling-equipment experience is a plus.

• Excellent written and oral communication skills, with the ability to communicate clearly across technical and operational teams.

Castelion offers a generous benefits package. Please refer to the bottom of our Careers page for more details.

Other Duties

Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice.

Additional Eligibility Requirements

This position may require access to classified information or restricted U.S. Government sites, systems, or information, as determined by the Company and/or applicable U.S. Government requirements. If the position is so designated, your employment in the role may be contingent upon your ability to obtain and maintain the required U.S. Government security clearance or other government authorization, and to satisfy any citizenship or other eligibility requirements imposed by applicable law, regulation, executive order, or government contract requirements. You will be notified if and when such requirements apply.

Affirmative Action/EEO Statement

Castelion is an Equal Opportunity Employer. We are committed to providing equal employment opportunities to all applicants and employees without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, genetic information, protected veteran status, or any other characteristic protected by applicable federal, state, or local law.

Castelion is committed to providing reasonable accommodations to qualified individuals with disabilities throughout the application and hiring process. If you require a reasonable accommodation to complete an application, participate in the interview process, or otherwise participate in the hiring process, please contact hr@castelion.com. Requests for accommodation will be considered on an individual basis and handled in accordance with applicable law.

Castelion is committed to fostering a workplace where employment decisions are based on qualifications, business needs, and the ability to perform the essential functions of the role, with or without reasonable accommodation.

EAR/ITAR Requirements

This position requires access to export-controlled information, and as such, employment (or hiring of a contractor) is contingent upon the candidate’s ability to access all applicable export-controlled information without additional export licensing being required by the Bureau of Industry and Security and/or the Directorate of Defense Trade Controls.