Industrial Engineer

Job Title: Industrial Engineer

Location: Warsaw, Indiana

Level: Senior

Client Facing: Yes

About PAC Group:

At The PAC Group (PAC), we specialize in engineering consulting, program management, and operational excellence—delivering high-impact solutions in more than 20 countries. We’re proud to partner with the world’s leading companies in automotive, aerospace, industrial, and technology sectors, providing strategic guidance and hands-on execution that drive innovation and efficiency. Whether we’re launching advanced manufacturing systems, deploying digital simulation tools, or scaling global operations, PAC thrives at the intersection of technology, engineering, and problem-solving.

Joining PAC means joining a dynamic, fast-paced, and global team that values curiosity, collaboration, and continuous improvement.

Role Purpose:

The Industrial Engineer serves as the architect of the organization’s operational efficiency. Their primary mission involves optimizing complex systems by integrating people, equipment, and materials into a seamless, high-performance manufacturing environment. In this role, the engineer bridges the gap between design and production, utilizing data-driven insights to eliminate waste, maximize throughput, and ensure operations scale effectively to meet global demand.

Key Responsibilities:

• Process Design & Optimization: Conduct comprehensive time and motion studies to establish standard work parameters. Analyze and redistribute workloads to eliminate bottlenecks and deploy a customized Lean toolkit (5S, Kanban, and SMED) to reduce changeover times.
• Capacity Planning & Resource Management: Evaluate production capacity against new product requirements and demand forecasts. Calculate required headcount and machinery (CapEx) and provide data-driven justifications for capital equipment procurement.
• Layout & Material Flow: Develop optimized 2D/3D plant layouts to maximize square footage. Streamline material flow to reduce transit waste and perform workstation assessments to ensure operator safety and minimize fatigue.
• Cost Analysis & Continuous Improvement: Perform detailed cost analyses per process step to identify high-variance areas. Monitor OEE, yield rates, and labor efficiency KPIs to lead targeted continuous improvement projects aimed at unit-cost optimization.
• Quality & Safety Integration: Develop and document formal work instructions compliant with quality and safety standards. Support Root Cause Analysis (RCA) for process related issues.
• New Program Support: Facilitate DFM/DFMA reviews during design phases to ensure seamless manufacturability. Conduct Process Capability Studies (Cp/Cpk) to validate tooling readiness and provide on-site stabilization support for new production lines.

Required Qualifications:

• Bachelor’s degree in Industrial, Manufacturing, or Mechanical Engineering.
• 5+ years of experience in an industrial engineering role within a manufacturing environment.
• Proficiency in AutoCAD (2D/3D), Microsoft Excel (advanced), and data analysis tools.
• Strong knowledge of Lean Manufacturing, Six Sigma, and time study techniques.
• Proven ability to present complex technical data to non-technical stakeholders and lead cross-functional teams.
• Skills in managing large-scale capital equipment projects from inception to launch.
• Ability to provide immediate, on-floor issue resolution during critical build phases.
• Interfacing effectively with different stakeholders, including design engineers, production teams, and outside vendors.
• Exceptional verbal and written skills for authoring specifications and presenting technical status updates.
• Ability to perform under pressure during high-stakes "launch phases" and adjust to changing build requirements.

Preferred Qualifications:

• Lean Six Sigma Green or Black Belt Certification.
• Experience with simulation software.