Digital Twin Engineer

Role Summary

Digital Twin 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