Sr Simulation Engineer

Key Responsibilities

1. SimulationLed Assessment & Data Discovery

• Lead the simulationspecific assessment of the Manufacturing plant, including structured walkthroughs of:
• Demand planning, scheduling, blending, tank farm operations, filling lines, QA stations, and warehouse flows
• Manual vs. automated process steps and decision points
• Identify data availability, validity, gaps, and assumptions required for accurate simulation modeling, covering:
• Batch cycle times, blending durations, QA delays
• Tank capacities, cleaning rules, routing constraints, contamination rules
• Filling line speeds, downtime, changeovers, rework, and leakage handling
• Assess and validate existing rulebased logic, constraints, and decision heuristics used across planning and execution systems.

2. EndtoEnd Plant Simulation Model Development

• Design and develop a plantlevel, endtoend simulation model using Siemens Tecnomatix Plant Simulation with Fluid Library, covering:
• Blending operations and fluid flow logic
• Tank selection, routing, flushing, and balancing
• Integration between blending and filling lines
• Warehouse interactions and WIP behavior
• Create AsIs state simulation models to establish a credible operational baseline (OEE, throughput, bottlenecks, WIP).
• Develop ToBe scenarios to evaluate:
• Automation and closedloop control introduction
• MES/MOM enablement
• Scheduling and rule optimization
• Ensure the model clearly demonstrates quantified benefits across productivity, throughput, and inventory reduction.

3. Tooling & Architecture Alignment

• Evaluate and articulate the appropriate use of simulation vs. design tools, clearly distinguishing:
• Technomatics Plant Simulation for process flow and OEE analysis
• COMOS for P&ID, pipelines, and engineering documentation (nonsimulation use)
• Align simulation logic with the existing systems landscape, including:
• SAP PP/MM/QM/EWM
• OMP / OPR planning and scheduling tools
• SCADA / DCS / PLC layers
• Ensure simulation assumptions reflect realworld system constraints and integration points.

4. Client Engagement & OnSite Delivery

• Work onsite at Customers Manufacturing facility for an extended assessment and modeling phase (expected 45 weeks).
• Engage directly with plant operations, engineering, IT/OT, and planning stakeholders to:
• Validate process understanding
• Capture undocumented rules and tribal knowledge
• Review simulation outputs and scenarios
• Support executivelevel discussions by translating simulation outcomes into clear, decisionready insights.

Required Skills & Experience

Mandatory

• 812+ years of experience in manufacturing process simulation
• US Business Visa (B1)
• Handson expertise with Siemens Tecnomatix Plant Simulation, including Fluid Library
• Proven experience modeling:
• Batch and process industries (blending, tanks, filling, fluid flows)
• Manual vs. automated manufacturing environments
• Strong understanding of:
• OEE, throughput analysis, bottleneck identification
• Manufacturing planning, scheduling, and execution logic
• Ability to translate ambiguous plant realities into structured simulation logic

Preferred

• Experience in chemical, oil & gas, or process manufacturing plants
• Exposure to SAPcentric manufacturing landscapes (PP, QM, EWM, PM)
• Understanding of closedloop automation, MES/MOM concepts, and OTIT integration
• Prior onsite assessment and consultingstyle engagements with manufacturing clients

Soft Skills & Mindset

• Practitioner mindset with strong problemstructuring ability
• Comfortable operating in datapoor, ambiguityrich environments
• Clear communicator able to engage plant engineers and senior leaders alike
• Collaborative approach aligned with crossfunctional and global teams