Modeling and Simulation Engineer
About The Position
The Manufacturing Digital Twin Engineer owns and builds the plant-level Digital Twin for an IATF-certified automotive manufacturing facility (~375 employees) producing Heavy Duty and Industrial Air and Liquid Filtration. The role involves developing this capability from the ground up using AutoCAD and FlexSim to model end-to-end production and internal logistics, run mixed-methods simulations, and provide data-driven recommendations to improve throughput, robustness, and investment decisions. A key aspect of the role is creating reusable standards and templates for global scaling. The position requires establishing and maintaining a governed model structure, keeping it aligned with real-world conditions, updating flows and process steps, maintaining capacity inputs, and modeling internal logistics. The engineer will also validate and refresh inputs with stakeholders, run various simulation studies for bottlenecks, constraint behavior, and line balancing, and evaluate buffer sizing, material flow improvements, staffing concepts, and operating policies. Furthermore, the role supports investment/expansion scenarios, identifies new Digital Twin use cases, builds repeatable templates for analyses, and communicates results and recommendations to leadership.
Requirements
- Bachelor's degree in Engineering or equivalent combinations of education and/or experience
- 3 to 5 years of manufacturing engineering, industrial engineering, simulation engineering, or related roles in a manufacturing environment
- Hands-on experience building models in FlexSim (or comparable DES tool)
- Experience using AutoCAD for industrial/manufacturing layouts
- Discrete-event simulation (DES) capability
- Proficiency in FlexSim including building reusable model components
- Proficiency in AutoCAD in a manufacturing layout context
- Strong understanding of manufacturing systems (flows, constraints, variability, bottlenecks)
- Ability to create models from ambiguous inputs and validate with stakeholders
- Strong analytical and communication skills; ability to explain assumptions/results to non-simulation audiences
- Ability to provide training and coach team members on the use of FlexSim to support simulation modeling, analysis, and decision-making
Nice To Haves
- Experience working in the automotive industry
- Basic scripting/analytics exposure: SQL, Python, PowerBI
- Using MES and SAP data for operational analysis
- Optimization approaches: DOE, parameter sweeps, heuristic optimization
Responsibilities
- Own the plant Digital Twin in AutoCAD + FlexSim
- Establish governed model structure (assets, routings, constraints, assumptions, versioning)
- Keep the model aligned to real-world conditions (including high-mix/low volume realities)
- Update flows/routings/process steps end-to-end
- Maintain capacity inputs: cycle times, changeovers, uptime/downtime
- Maintains shift/labor patterns, buffers/WIP rules, operating constraints
- Model internal logistics: warehouse/supermarkets, tugger/forklifts routes, replenishment logic
- Validate and refresh inputs with stakeholders using MED and SAP data
- Run studies for bottlenecks, constraint behavior, line balancing, rate changes
- Evaluate buffer sizing/WIP strategies, material flow improvements
- Assess staffing concepts and operating policies
- Support investment/expansion scenarios (new lines, automation, warehouse, redesign)
- Use DOE/parameter sweeps, heuristic optimization, structured experimentation
- Identify new Digital Twin use cases with Manufacturing Engineering, Supply Chain, CI/Lean
- Translate operational problems into simulation questions with defined inputs/outputs
- Build repeatable templates for recurring analyses
- Provide recommendations supporting capex justification, investment prioritization, through output improvements, and robustness/sensitivity analysis
- Communicate results to leadership with clear assumptions, scenarios, findings, and recommendation
- Validate alternative layouts/logistics concepts/capacity changes through simulation
- Collaborate with engineering while protecting model integrity and ownership
- Partner with the Global Digital Twin Program Lead
- Package reusable standards: templates, modeling conventions, scenario libraries
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What This Job Offers
Job Type
Full-time
Career Level
Mid Level
Number of Employees
1,001-5,000 employees
