Process Engineer - Fulfillment Center

Abacus Solutions Group is currently recruiting for a Process Engineer to be based out of a facility in Northeast, MD area. Bilingual in English and Spanish is required!

Summary: Design, analyze, and continuously improve fulfillment and distribution center operations for web (e-commerce) and retail channels. Partner with operations, IT, and supply chain teams to optimize order flow, labor productivity, inventory accuracy, and on-time shipment performance — while maintaining a safe and scalable work environment during both steady-state and peak periods.

Responsibilities:

Order Fulfillment & Flow Optimization

Map and re-engineer end-to-end order flows: receiving → putaway → picking → packing → shipping for both web and store replenishment orders

Analyze order profiles (unit count, SKU mix, order size, wave patterns) to optimize slotting, pick paths, and batch/zone strategies

Design and refine conveyor, sortation, and packing line layouts to maximize throughput and minimize touches

Partner with WMS/WCS teams to configure system rules, labor management, and directed work logic

Labor & Productivity

Develop engineered labor standards (ELS) and time studies for all FC roles (pick, pack, receive, ship)

Build staffing models aligned to volume forecasts, SLA targets, and peak planning (holiday, Prime-style events)

Identify productivity gaps via LMS data and drive targeted improvement projects

Support ergonomic assessments and workstation redesign to reduce injury rates

Continuous Improvement & Projects

Lead Kaizen events, DMAIC projects, and rapid improvement workshops across all FC departments

Reduce defects: mispicks, mis-ships, packaging damage, and returns driven by FC errors

Own capital project lifecycle — business case, layout design, vendor selection, installation, and go-live

Evaluate and pilot automation technologies: AMRs, goods-to-person systems, print-and-apply, automated packing

Data, Reporting & Compliance

Build and maintain FC dashboards: units per hour (UPH), dock-to-stock time, order cut-off compliance, ship-on-time rate

Develop SOPs, job aids, and training materials for new processes and equipment

Ensure OSHA compliance and champion safety observation programs on the floor

Coordinate with retail and e-commerce demand planning teams on volume forecasts and capacity planning

Requirements:

B.S. in Industrial, Mechanical, Systems, or Supply Chain Engineering.

2–5 years in fulfillment, distribution, or logistics engineering. E-commerce or omnichannel Distribution Center experience strongly preferred.

Bilingual in English and Spanish is required.

WMS (Manhattan, Blue Yonder, SAP EWM), LMS, AutoCAD/SketchUp for layouts, Excel/SQL/Power BI, Minitab or similar.

Six Sigma Green/Black Belt, Lean certification, or APICS CSCP/CLTD a plus. PMP helpful for capital project roles.