Heads Up: Senior Industrial Engineer

Location:

Buffalo, NY, USA

Salary: $ USD Annually - $ USD Annually

Senior Industrial Engineer – Capacity & Capability Planning

Location:

Tempe, AZ | Buffalo, NY | Wilmington, NC

Travel: 90-100% Global Travel Required

Our client is a rapidly growing manufacturer supporting the expanding data center infrastructure market. As the organization continues to scale, we are seeking a highly experienced Senior Industrial Engineer to lead capacity and capability planning initiatives across a global manufacturing network.

This is a high-impact role responsible for evaluating manufacturing capacity, identifying constraints, developing expansion strategies, and supporting new facility launches, joint ventures, and major production growth initiatives. The position offers significant visibility and the opportunity to influence strategic manufacturing decisions across multiple domestic and international operations.

The Senior Industrial Engineer - Capacity & Capability Planning will lead enterprise and site-level manufacturing capacity analysis, capability assessments, and strategic planning activities. This individual will develop demand-to-capacity models, evaluate manufacturing readiness, identify bottlenecks, and provide data-driven recommendations to support future growth.

Working closely with Operations, Manufacturing Engineering, Supply Chain, Quality, Finance, Facilities, Automation, and executive leadership, this role will ensure manufacturing capabilities align with business objectives while meeting safety, quality, cost, delivery, and capacity requirements.

• Develop and maintain manufacturing capacity models at the site, process, equipment, and enterprise levels.
• Translate demand forecasts, product mix, cycle times, staffing plans, OEE, shift schedules, and downtime assumptions into capacity requirements and forecasts.
• Conduct manufacturing capability assessments across facilities, equipment, tooling, labor, processes, and infrastructure.
• Identify bottlenecks, capacity constraints, single points of failure, and operational risks across fabrication, assembly, testing, warehousing, and material handling operations.
• Create and evaluate scenarios involving production growth, product mix changes, labor strategies, equipment investments, outsourcing, in sourcing, facility expansions, and new manufacturing sites.
• Establish and standardize methodologies for capacity planning, utilization modeling, OEE analysis, takt time calculations, staffing models, and constraint analysis.
• Perform line balancing, labor planning, throughput analysis, work-in-process analysis, and sensitivity studies.
• Develop recommendations for debottlenecking, capital investments, make-versus-buy decisions, automation opportunities, and manufacturing footprint optimization.
• Validate production assumptions through analysis of actual manufacturing performance and operational metrics.
• Build and maintain long-range capacity and capability roadmaps aligned with business growth plans and product introductions.
• Support capital planning for equipment, tooling, automation, facilities, utilities, and infrastructure investments.
• Proactively identify manufacturing risks and develop mitigation strategies related to capacity, labor availability, process limitations, equipment reliability, supplier constraints, and demand fluctuations.

• Demand-to-capacity models across sites, product families, and production processes.
• Capacity analyses including rated, practical, demonstrated, and required capacity.
• Bottleneck identification and constraint analysis.
• Utilization, labor, shift, and OEE scenario planning.
• Capacity gap forecasts…