Simulation Engineer

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What we offer:

At Magna, you can expect an engaging and dynamic environment where you can help to develop industry-leading automotive technologies. We invest in our employees, providing them with the support and resources they need to succeed. As a member of our global team, you can expect exciting, varied responsibilities as well as a wide range of development prospects. Because we believe that your career path should be as unique as you are.

Group Summary:

The Magna Exteriors portfolio of products includes access systems such as liftgates, exterior trim, modular systems, front-end modules including fascia, active aerodynamic systems and other lightweight structural components for automotive, commercial truck and other industrial markets.

Recognized globally as an innovator in all aspects of vehicle exteriors, Magna provides everything needed, from materials development and design through manufacturing and assembly, to help automakers create sleek, state-of-the-art vehicles across the world.

Job Responsibilities:

Specific Job Duties:

• Develop digital twins of new equipment and manufacturing processes, enabling early validation of cycle times, process flows, machine behavior, ergonomics, and throughput before physical design or build begins.

• Create and maintain full-facility digital twins for:

o Norplas - including molding, paint, assembly, material flow, and automation systems

o MEHP (Highland Park) - assembly operations, buffer zones, staffing models, and equipment interactions

o MEBT (Brownstown) - assembly flow, workstation performance, and automation integration These models will support continuous improvement, capital planning, and real-time scenario evaluation.

• Perform automated material flow studies, using simulation tools to assess part movement, buffer sizing, WIP levels, AGV or conveyor routing, operator travel, and material presentation strategies.

• Validate machine and process concepts during quoting and early design, providing cycle time modeling, utilization analysis, bottleneck detection, and performance projections to support accurate ROI and staffing estimates.

• Collaborate with the Industrial Engineer to evaluate workflow efficiency, equipment capacity, labor requirements, and station balancing using simulation-driven insights.

• Support the Equipment Project Engineer by simulating equipment designs and layouts to identify risks, confirm design feasibility, and ensure equipment will meet production throughput requirements.

• Model automation and OT system interactions, including PLC/HMI sequencing, robot timing, safety interlock behavior, and MES data exchange to identify integration risks prior to commissioning.

• Conduct "what-if" scenario modeling to evaluate changes in volume, shift structure, staffing, equipment capability, or material flow, providing data-driven recommendations for operational decision-making.

• Analyze potential failure modes in equipment and processes, using simulation outputs to support PFMEA development and to identify mitigation strategies for mechanical, controls, or material flow risks.

• Optimize plant layouts and workcell configurations, using digital twins to assess visibility, safety clearances, ergonomic posture evaluation, operator reach, and maintenance access requirements.

• Assist with Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT) by validating simulation accuracy against real machine performance, identifying discrepancies, and recommending process tuning.

• Develop reusable simulation templates and standards, establishing best practices for modeling equipment, robots, conveyors, operators, and material flow to support consistent simulation capability across all facilities.

• Provide regular reporting and visual outputs, including throughput charts, heat maps, animation videos, bottleneck analysis, and cycle time comparison dashboards for leadership and project teams.

Educational Requirements

• A bachelor degree in an Engineering Science or Technology area.

• Exposure to DFMA, synchronous manufacturing, and ergonomics.

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Related Work Experience:

• Previous experience in a manufacturing environment.

• Proficient computer skills a must (Word, Excel, Project, AutoCAD)

• Proficient computer skills a Bonus (FlexSim, Visual Components)

• Proficient automation skills a Bonus (PLC, Robotic, Machine Design)

• Demonstrated ability to work with a minimal supervision and participa