Digital Twin Engineer (Manufacturing Simulation)

Role Summary

Job Description

Modeling and Simulation Engineer

MANN HUMMEL

Onsite - Gastonia, NC

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 develops the capabaility 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 throughout, robustness, and investment decisions - while creating reusable standards/templates for global scaling.

Main Tasks

• 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 contraints
• 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 prioritizaiton, 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 ownnership
• Partner with the Global Digital Twin Program Lead
• Package reusable standards: templates, modeling conventions, scenario libraries
  
  

Profile

Education

• Bachelors degree in Engineering preferred
• Equivalent combinations of education and/or experience will be considered.
  
  

Experience

• 3 to 5 years of manufacturing engineering, industrial engineering, simulation engineering, or related roles in a manufacturing environment
• Tool/application experience: hands-on building models in FlexSim (or comparable DES tool) and using AutoCAD for industrial/manufacturing layouts.
  
  

Skills & Competencies

• Discrete-event simulation (DES) capability
• FlexSim including building reusbale model components
• AutoCAD in manufacturing layout context
• Strong understanding of manufacturing systems (flows, constraints, variability, boittlenecks)
• Ability to create models from ambiguous inputs and validate with stakeholders
• Strong analytical and communication skills; explain assumptions/results to non-simulations audiences
• Provide training and coach team members on the use of FlexSim to support simulation modeling, analysis, and decision-making
  
  

Preferred Experience

• 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