Simulation Design Engineer

Process Simulation Engineer - BIW Tooling & Fixtures

Location: Southfield, MI

Pay: $30-$34/hour

Type: Long-Term Contract-to-Hire

Travel: 5-20% (Domestic and occasional International)

Position Overview

We are seeking a Process Simulation Engineer to support Body-in-White (BIW) tooling and robotic assembly simulation for automotive body shop programs. This role focuses on developing and validating manufacturing processes using Siemens Process Simulate , ensuring robotic systems, tooling fixtures, and assembly operations meet cycle time, feasibility, and safety requirements.

The ideal candidate has experience working in automotive body shop environments , strong robotics simulation knowledge , and familiarity with BIW tooling and assembly strategies .

Process Simulation & Validation

• Perform process feasibility studies and manufacturing simulations for BIW assembly operations.
• Develop 3D simulation models of robotic cells, tooling, and production lines.
• Simulate robotic operations and human tasks within a digital manufacturing environment.
• Validate cycle time, reachability, and process feasibility using simulation tools.
• Conduct reach studies, swept volume analysis, and interference checks .

Robotic Programming & Optimization

• Develop and optimize offline robot programs (OLP) for multiple robot platforms including ABB, FANUC, KUKA, and Comau .
• Configure and utilize Robot Controller Simulation (RCS) to validate robotic motion.
• Optimize robot paths, weld distribution, and process flow to improve cycle time and efficiency.
• Download and validate offline robot programs in native robot languages .

BIW Process & Tooling Development

• Support robotic welding, sealing, and assembly processes within BIW manufacturing.
• Define equipment selection and layout , including robots, conveyors, and tooling fixtures.
• Assist with tool validation and process verification prior to manufacturing.
• Develop robot kinematics models, weld gun configuration, and joint distribution strategies .

Collaboration & Technical Suppor t

• Work closely with customers, system engineers, and project teams to gather requirements and develop solutions.
• Support customer design reviews and technical presentations .
• Create technical documentation, simulation reports, and visualizations to communicate results.
• Provide site and technical support during implementation phases .

Required Skills & Experience

Core Technical Skills

• 4-5+ years of experience in process simulation or robotic simulation within automotive body shop environments .
• Strong proficiency with Siemens Process Simulate .
• Experience with BIW tooling fixtures and body shop assembly strategies .
• Knowledge of robot programming and automation processes .

Robotics & Automation

• Experience with major robot platforms such as:
• ABB
• FANUC
• KUKA
• Comau
• Motoman or Kawasaki
• Experience with robotic processes such as:
• Spot Welding
• Arc Welding
• Sealing / Dispensing
• Material Handling
• Riveting or Assembly

Engineering & Simulation Tools

• Experience with 3D CAD tools such as:
• NX
• CATIA
• SolidWorks
• Experience with simulation tools such as:
• Siemens Process Simulate
• Delmia
• Robcad
• Working knowledge of AutoCAD and Microsoft Excel .

Manufacturing Knowledge

• Understanding of body shop manufacturing processes and line layouts .
• Knowledge of robot-to-PLC communication and IO structures .
• Familiarity with industrial safety standards (OSHA, NIOSH) .
• Strong mechanical understanding of industrial automation equipment and machinery .

Education

• Associate's Degree or higher in Mechanical Engineering, Mechanical Technology, or related field , OR
• Equivalent experience with 5+ years in mechanical design, manufacturing engineering, or automation engineering .

The Process: To apply for this position, please follow these steps: Apply for this job with your current resume. We'll get back to you the same day with some feedback on your application. Next you'll be invited to an online screening conversation so we can go over the job requirements together and you can ask questions. After this stage we'll give you more feedback on your application and select the candidates to move forward in the process. Typically steps 1 to 4 takes less than 24 hours.

HRU is an Equal Opportunity Employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.

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