Sr Lean and Process Simulation Engineer

Role Purpose

Are you passionate about using simulation, data analytics, and Lean Manufacturing to transform manufacturing operations?

Join our team as a Lean & Process Simulation Engineer and help drive manufacturing transformation through advanced process simulation, capacity analysis, automation modeling, and data-driven decision-making. This role offers the opportunity to develop innovative solutions that improve productivity, optimize resources, and support the design of future-state manufacturing systems.

What is your role?

As a Lean & Process Simulation Engineer, you will be responsible for developing, validating, and utilizing process simulation models to support manufacturing transformation, Lean initiatives, automation projects, capacity planning, and future-state process design.

You will convert manufacturing data, layouts, workflows, routings, cycle times, and operational assumptions into discrete-event simulation models that enable the organization to evaluate scenarios, identify bottlenecks, optimize resource utilization, and support strategic business decisions.

Working closely with Operations, Manufacturing Engineering, Automation, Industrial Engineering, Planning, Supply Chain, Logistics, Quality, and Continuous Improvement teams, you will ensure simulation models accurately represent current and future manufacturing environments.

Key Responsibilities

• Lead the development, validation, and maintenance of discrete-event simulation models for manufacturing, warehouse, material flow, assembly, testing, automation, and logistics processes.
• Develop simulation inputs based on operational baselines including cycle time, takt time, MCT, TWC, throughput, WIP, capacity, utilization, productivity, labor requirements, equipment constraints, and routing logic.
• Support Lean Manufacturing and continuous improvement initiatives by validating future-state scenarios, VSM proposals, layout changes, line balancing, standard work, material flow, and waste reduction opportunities.
• Build and analyze simulation scenarios to evaluate capacity, bottlenecks, equipment utilization, operator movement, transporter paths, conveyor systems, inventories in process, resource allocation, and process flow performance.
• Support automation and manufacturing transformation projects by simulating manual, semi-automated, and automated processes, including robots, conveyors, AGVs, ASRS, forklifts, operators, machines, work teams, and material handling systems.
• Import, validate, and update CAD layouts, process routes, product flows, work centers, and system assumptions to ensure simulation models are aligned with actual and future-state manufacturing conditions.
• Design and run what-if scenarios, experiments, replicas, and optimization studies to support business decisions related to equipment validation, headcount, throughput, labor allocation, scheduling, cost evaluation, and technology implementation.
• Develop simulation reports, dashboards, statistical analysis, 2D/3D graphics, Gantt charts, KPI outputs, and presentations to communicate model results, risks, recommendations, and improvement opportunities to cross-functional teams and leadership.

Experiences/Education - Required

• 5+ years of related experience in process simulation, Industrial Engineering, manufacturing systems, Lean Manufacturing, automation, logistics, warehouse operations, or manufacturing transformation.
• Proven experience developing and validating discrete-event simulation models for manufacturing, warehouse, material flow, assembly, testing, automation, or logistics processes.
• Experience using simulation tools such as FlexSim, Siemens Tecnomatix Plant Simulation, Simul8, ProModel, Arena, or similar software.
• Experience with capacity analysis, time studies, process flow, line balancing, resource allocation, bottleneck analysis, layout validation, and productivity improvement.
• Familiarity with manufacturing software systems such as SAP, ERP, MES, PLM, CAD tools, and data visualization platforms.
• Experience supporting automated, semi-automated, high-volume, multi-product, warehouse, material handling, or complex manufacturing environments preferred.
• Conversational English

Experiences/Education - Desired

• Advanced knowledge of FlexSim, Plant Simulation, Simul8, ProModel, Arena, or similar simulation software preferred.
• Experience with CAD/layout tools such as AutoCAD, SolidWorks, SketchUp, or similar platforms.
• Knowledge of Lean, Six Sigma, KT, AME, OPEX, and manufacturing excellence tools.
• Knowledge of SAP, ERP, MES, routing logic, BOMs, and manufacturing master data preferred.
• Experience with Power BI, Excel, Minitab, Visio, PowerPoint, or similar data/reporting tools.
• Knowledge of automation, conveyors, AGVs, robots, ASRS, forklifts, operators, machines, and material handling systems.
• Experience with Digital Twin concepts, real-time data integration, Industry 4.0, or advanced manufacturing technologies preferred.
• Self-motivated, analytical, independent, flexible, quick learner, and able to deliver results under tight deadlines

What do we offer?

• Competitive compensation and comprehensive benefits package.

• Opportunities for professional growth and career advancement.

• Exposure to high-impact manufacturing transformation and automation projects.

• Collaborative and dynamic cross-functional work environment.

• Opportunities to lead operational excellence and continuous improvement initiatives.

• Continuous learning and development programs.

• The opportunity to make a significant impact on manufacturing performance, cost optimization, and business success.

Join us and help shape the future of manufacturing through innovation, operational excellence, and continuous improvement.