Position Summary:

The Lean Material Flow Specialist is directly responsible and accountable for the tactical and real-time execution of Lean material flow within a chemical processing environment. This includes inventory kitting, staging, replenishing, returning, and direct digital/material accountability from warehouse through line-side, changeover, and end-of-run. The Specialist acts as the subject matter expert on inventory accuracy, material readiness, and buffer management, enabling higher operator value-add time and improved reliability – all in compliance with PSM, OSHA, HazCom and facility protocols.

Essential Duties:

Review production schedules, batch records, and inventory data to prepare kitting and staging requirements for raw materials, packaging, and consumables.
Pick, kit, label, stage, and issue materials to production lines to ensure accurate, timely availability.
Replenish line-side, staging, and buffer inventory based on production demand and changing priorities.
Reconcile physical and system inventory in SAP/ERP; investigate, escalate, and help resolve discrepancies affecting production readiness.
Support changeovers and machine setup by aligning staged materials to production needs to reduce downtime.
Manage returns, scrap, empties, and by-products to maintain organized work areas, material traceability, and compliance.
Collaborate with Material Handlers and Warehouse Manager to coordinate material movement between warehouses, secondary storage, and production areas to maintain continuous flow.
Monitor shortages, stockouts, and bottlenecks; communicate proactively with production, warehouse, and shift leadership.
Maintain accurate material transactions, labeling, and documentation to support inventory control and regulatory standards.
Assist with cross-shift, weekend, and contingency coverage plans, while supporting 5S and continuous improvement in staging and material flow processes.

Success Criteria:

Material Flow Reliability: ≥98% on-time completion of workstation replenishment with zero unplanned stockouts at point-of-use stations.
Safety & Compliance Excellence: Zero incidents, spills, exposures, or regulatory findings; 100% adherence to PSM, OSHA, HazCom, RCRA, DOT, and spill prevention protocols.
Inventory & Pull System Accuracy: ≥99% POU inventory match during audits.
Waste & Contamination Control: Zero accumulation of empties/hazardous waste at workstations and zero cross-contamination events.
Operator Support Effectiveness: ≥95% reduction in operator material-fetching interruptions (via audits/feedback); on-time assistance for ≥95% of changeovers.

Qualifications:

High school diploma or equivalent; technical/chemical-related certification preferred.
1–2 years in chemical manufacturing, material handling, or production support; hazardous materials experience a plus.
Knowledge of Lean principles (JIT, Kanban, waste reduction) and regulated process industries.
Strong time management, reliability, and ability to follow precise routes/schedules.
Physical ability to walk extensively, handle carts/tuggers/dollies, and lift up to 50 lbs while wearing PPE (respirators, suits, etc.).
Safety-focused mindset with attention to detail, quality, and regulatory compliance.
Good communication/teamwork; basic ERP/scanner skills.

Work Environment /Physical Demands:

Work Environment: Primarily on the chemical production floor with high mobility across reactors, mixers, filling lines, storage areas, and waste zones; exposure to typical manufacturing conditions including noise, chemical odors, varying temperatures, potential hazardous atmospheres, and strict PPE-required areas (e.g., respirators, protective clothing, gloves); adherence to PSM, OSHA, HazCom, RCRA, and facility safety protocols is mandatory at all times.

Physical Demands: Extensive walking and standing for most/all of the shift while following replenishment routes; frequent pushing/pulling of carts, tuggers, drum dollies, or material handling equipment; lifting, carrying, and moving loads up to 50 lbs (e.g., containers, drums, supplies); bending, stooping, and reaching to handle materials or replenish stations; sustained physical activity to maintain pace and reliability in a fast-moving, safety-critical setting.

Additional Considerations: Must wear full required PPE continuously; ability to respond quickly to alerts or needs without compromising safety; role requires good balance, stamina, and dexterity for precise handling of chemicals and equipment to prevent spills, exposures, or cross-contamination.

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