Simulation Engineer, Factory Design; DES

Simulation Engineer, Factory Design (DES)

Location: Remote, USA (potential rare site visit to Normal, IL)

Duration: 6-month contract

Pay Range: $49–54/hour

A leading electric vehicle manufacturer’s Factory Design & Simulation team is seeking a contract Simulation Engineer (DES) to support early-stage manufacturing engineering and throughput architecture for an upcoming vehicle program launch.

This role focuses on building and analyzing discrete event simulation (DES) models to inform factory and production line design decisions prior to RFQ and detailed engineering phases.

You will collaborate cross-functionally with teams across Body, General Assembly, Paint, Battery, Drive Unit, and Material Flow to validate capacity, size buffers, and identify bottlenecks impacting launch and ramp-up.

• Build discrete event simulation models (Flex Sim preferred) for manufacturing and material flow systems (e.g., inter-shop buffers, ASRS sizing, AGV flows, overspeed trade-offs).
• Translate high-level factory inputs (demand, shift patterns, product mix, FPY, MTBF/MTTR) into simulation-ready assumptions and scenarios.
• Conduct scenario and sensitivity analyses using experiment tools to:
  • Validate jobs per hour (JPH) against targets
  • Quantify overspeed, OPR/TEE, and buffer requirements
  • Assess jobs per shift (JPS) consistency and risk
• Deliver clear, decision-focused reports and presentations outlining trade-offs (throughput, risk, space).
• Collaborate with layout, material flow, and industrial engineering teams to ensure alignment with production assumptions and constraints.
• Follow established DES modeling standards, including structure, naming, documentation, and handoff processes.

• 3+ years of experience in automotive manufacturing engineering (e.g., body, paint, GA, battery, drive unit, or material flow).
• Proven ownership of discrete event simulation projects.
• Expert-level proficiency with Flex Sim (Autodesk).
• Experience modeling:
  • Multi-line assembly systems with buffers and rework
  • Stochastic processes (failures, repairs, variability)
  • Throughput, capacity, and bottleneck analysis
• Strong understanding of manufacturing KPIs:
  • JPH, JPS, OEE/TEE, MTBF/MTTR, WIP, buffer sizing
• Ability to structure input data, define scenarios, and clearly communicate assumptions and limitations.
• Strong communication skills, with the ability to translate complex simulation outputs into actionable insights.

• Experience with Flex Script, Python, or C++ for custom simulation logic.
• Background in industrial engineering.
• Experience with greenfield factory design or major production ramp-ups.
• Preference for candidates in CST or EST time zones

...