Kyle O'Brien
Solutions Engineering Manager
Specialties:
Warehouse Automation · Solution Design · Simulation · Slotting · Operations Research · Engineering Leadership
Location:
San Francisco Bay Area
Skills:
Python · SQL · FlexSim · Excel · Power BI · Tableau · Databricks
Email:
Professional Experience
I’m an industrial engineer and solutions leader specializing in warehouse automation, simulation, and the design of complex fulfillment systems.
My career has progressed from hands-on modeling and operational analysis to solution architecture, customer strategy, engineering process development, and team leadership. I have supported projects across retail, e-commerce, food and beverage, healthcare, manufacturing, and third-party logistics.
My work is centered on turning incomplete operational data and complex requirements into clear, defensible engineering decisions. That includes developing warehouse concepts, sizing automation systems, validating performance through simulation, building reusable analytical tools, and communicating technical recommendations to customers and business leaders.
Today, I lead solutions engineering initiatives focused on improving how automation opportunities are analyzed, designed, validated, and presented. I am particularly interested in creating scalable engineering methods that reduce manual effort, improve consistency, and allow technical teams to spend more time solving difficult customer problems.
Work Experience
July 2025 - Present
May 2023 - June 2025
June 2021 - May 2023
June 2020 - June 2021
Solutions Engineering Manager
Robust.AI | San Francisco Bay Area
Lead the solutions engineering function supporting Carter collaborative mobile robot deployments for warehouse and fulfillment operations.
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Lead discovery, operational analysis, solution design, simulation, fleet sizing, and technical recommendations.
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Manage and develop solutions engineers while establishing standards for technical quality and customer engagement.
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Built internal simulation and AI-enabled workflows that improve the speed and consistency of solution development.
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Partner with sales, product, engineering, and leadership to translate complex operations into practical automation solutions.
Automation Engineering Manager
Walmart and Sam’s Club | Remote
Supported the design, implementation, and continuous improvement of next-generation fulfillment centers totaling more than one million square feet.
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Simulated end-to-end material flow for fulfillment centers using conveyors, automated storage and retrieval systems, and collaborative robots.
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Created automation playbooks with operations, safety, and quality teams to standardize system operation and maintenance.
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Implemented Tableau and Grafana dashboards for automation performance reporting.
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Built data pipelines using Databricks, Google BigQuery, InformixDB, and web APIs.
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Developed a Python-based slotting application that improved units per hour by approximately 8% and optimized inventory placement across the Sam’s Club fulfillment network.
Simulation Team Lead and Research Scientist
FORTNA | Remote
Led simulation projects and developed analytical tools supporting complex warehouse and fulfillment-system designs.
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Recruited, interviewed, trained, and mentored a team of simulation engineers.
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Managed company-wide simulation projects for internal teams and external customers.
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Led simulation-based layout and process redesign for global retail clients, including programs valued at more than $500 million.
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Created a FlexSim toolset that reduced model-development time by more than 50%.
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Led algorithm development supporting the FORTNA warehouse execution system.
Engineering Consultant
Bastian Solutions | Indianapolis, IN
Supported the analysis and design of greenfield and brownfield warehouse and material-handling systems.
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Wrote and presented customer proposals for warehouse automation and facility-design projects.
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Performed time studies, simulation, slotting, and storage and automation sizing.
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Developed engineered labor standards for picking, packing, and replenishment operations.
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Conducted capacity analysis and return-on-investment calculations for automation and storage investments.
Education & Credentials
University of Louisville
Master of Engineering, Industrial Engineering
2020
Bachelor of Science, Industrial Engineering
2019
GPA: 3.95
Professional Certificates
Rutgers University Supply Chain Management Specialization
2026
Google Project Management Professional Certificate
2024
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