Engineering - Lead Engineer, Simulation & Engineering Analysis

Madison, IN, USA

The Simulation & Engineering Analysis Engineer is responsible for providing engineering analysis and simulation support throughout the product development process. This role partners closely with Product Engineering, CAD, Manufacturing Engineering, Program Management, Quality, and Test Engineering to evaluate product designs, identify risks early, and support successful product launches.

• Perform Finite Element Analysis (FEA) using ANSYS to evaluate product designs, including static structural, thermal, vibration, and modal analysis.
• Interpret simulation results and provide engineering reports containing recommendations that improve product performance, reliability, manufacturability, and cost.
• Perform Computational Fluid Dynamics (CFD) simulations using ANSYS to evaluate airflow, cooling performance, and other fluid-related design requirements.
• Present simulation findings and technical recommendations to engineering teams and leadership.
• Lead formal Engineering Design Reviews, facilitating cross‑functional discussions to identify technical risks and ensure product readiness.
• Collaborate with CAD Designers, Product Engineers, Manufacturing Engineers, Quality Engineers, Program Managers, and other stakeholders throughout the product development process.
• Support root‑cause investigations by using simulation tools to evaluate field failures, manufacturing issues, and design concerns.
• Maintain and improve the Engineering Knowledge Management database by documenting lessons learned, best practices, design guidelines, and technical standards.
• Assist in developing engineering standards, design guidelines, and simulation methodologies.
• Continuously improve simulation processes, workflows, and engineering tools.
• Support prototype evaluations and correlate simulation results with physical testing when applicable.

• Bachelor's degree in Mechanical Engineering, Engineering Mechanics, or a related discipline.
• Extensive experience performing Finite Element Analysis (FEA) using ANSYS.
• Strong understanding of structural mechanics, heat transfer, and vibration analysis.
• Proficiency in interpreting engineering drawings and 3D CAD models.
• Excellent analytical, problem‑solving, organizational, and communication skills.
• Ability to effectively collaborate across cross‑functional engineering teams while managing multiple projects in a fast‑paced environment.
• Preferred: eight or more years of experience using ANSYS for both FEA and Computational Fluid Dynamics (CFD) simulations.
• Preferred: at least two years of experience with Creo Parametric.
• Preferred: background in the automotive, transportation, or manufacturing industries.
• Preferred: experience with Design Failure Mode and Effects Analysis (DFMEA), engineering design reviews, structured product development processes, and the development of engineering standards, design guidelines, or knowledge management systems.