Digital Factory Engineer / Plant Simulation

Actalent is seeking a Plant Simulation Engineer to support the design, validation, and optimization of next-generation autonomous material flow

solutions across OEM manufacturing facilities. This role is responsible for creating and maintaining digital factory models using Siemens Plant Simulation to evaluate AGVs, AMRs, conveyors, production systems, and facility layouts before physical implementation. The engineer will leverage discrete event simulation (DES) and digital twin methodologies to analyze material flow, identify bottlenecks, validate manufacturing concepts, and provide data-driven recommendations that improve throughput, efficiency, and launch readiness. The ideal candidate combines simulation expertise with a strong understanding of manufacturing operations, production systems, and material flow. This role will work closely with manufacturing, controls, industrial engineering, operations, and automation teams to support the deployment of innovative material handling solutions across manufacturing facilities., Digital Factory Modeling

• Develop, maintain, and enhance digital factory models using Siemens Plant Simulation.
• Create discrete event simulation (DES) models representing manufacturing, assembly, logistics, and material handling operations.
• Model AGV/AMR fleets, conveyors, warehouses, staging areas, supermarkets, and production lines.
• Simulate future-state manufacturing concepts and evaluate operational performance prior to implementation.

Material Flow & Capacity Analysis

• Perform capacity and throughput analysis for Body Shop, Paint Shop, General Assembly, and supporting logistics operations.
• Evaluate jobs-per-hour (JPH), cycle times, utilizations, queue lengths, and bottleneck conditions.
• Analyze material flow strategies and recommend optimal transportation methods, buffer sizing, and equipment utilization.
• Support material handling network design and AGV fleet sizing activities.

AGV & Autonomous Material Flow

Optimization

• Simulate AGV and AMR traffic patterns, routing strategies, charging requirements, and fleet utilization.
• Evaluate autonomous material handling concepts and identify opportunities to improve safety, efficiency, and scalability.
• Quantify operational impacts of AGV deployments through simulation-based analysis.
• Support development of standardized AGV solutions for deployment across manufacturing facilities.

Manufacturing Launch Support

• Support new vehicle launches through simulation-based validation and risk assessment.
• Verify manufacturing concepts, layouts, and process designs before physical implementation.
• Identify operational constraints early in the launch process and recommend mitigation strategies.
• Validate production readiness and manufacturing performance targets.

Continuous Improvement &

Collaboration

• Partner with Manufacturing Engineers, Controls Engineers, Material Flow Engineers, Industrial Engineers, and Plant Operations teams.
• Develop business cases and recommendations based on simulation results.
• Present technical findings and improvement opportunities to plant leadership and stakeholders.
• Support continuous improvement initiatives focused on productivity, cost reduction, and operational excellence.

• Bachelor’s degree in:
• Industrial Engineering
• Manufacturing Engineering
• Mechanical Engineering
• Mechatronics Engineering
• Supply Chain Engineering
• Related Engineering discipline
• Experience using Siemens Plant Simulation.
• Experience developing discrete event simulation (DES) models.
• Understanding of automotive manufacturing processes and production systems.
• Knowledge of material flow, logistics, and manufacturing operations.
• Experience analyzing:
• Throughput (JPH)
• Cycle Times
• Capacity Utilization
• Buffer Sizing
• Bottlenecks
• Familiarity with Lean Manufacturing and Continuous Improvement methodologies.
• Strong analytical, problem-solving, and communication skills.
• Ability to present technical findings to both engineering and non-technical stakeholders., * Experience modeling AGVs, AMRs, automated storage systems, or material handling equipment.
• Automotive manufacturing experience.
• Experience supporting production launches or factory startup activities.
• Knowledge of warehouse operations, line-side delivery, and intralogistics systems.
• Experience with digital twin technologies and smart manufacturing initiatives.
• Exposure to AnyLogic, FlexSim, Simul8, AutoMod, or other simulation platforms.
• Knowledge of Industry 4.0 concepts and data-driven manufacturing systems.

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.