Key Responsibilities
1. Simulation‑Led Assessment & Data Discovery
- Lead the simulation‑specific assessment of the Manufacturing plant, including structured walkthroughs of:
- Demand planning, scheduling, blending, tank farm operations, filling lines, QA stations, and warehouse flows
- Manual vs. automated process steps and decision points
- Identify data availability, validity, gaps, and assumptions required for accurate simulation modeling, covering:
- Batch cycle times, blending durations, QA delays
- Tank capacities, cleaning rules, routing constraints, contamination rules
- Filling line speeds, downtime, changeovers, rework, and leakage handling
- Assess and validate existing rule‑based logic, constraints, and decision heuristics used across planning and execution systems.
2. End‑to‑End Plant Simulation Model Development
- Design and develop a plant‑level, end‑to‑end simulation model using Siemens Tecnomatix Plant Simulation with Fluid Library, covering:
- Blending operations and fluid flow logic
- Tank selection, routing, flushing, and balancing
- Integration between blending and filling lines
- Warehouse interactions and WIP behavior
- Create As‑Is state simulation models to establish a credible operational baseline (OEE, throughput, bottlenecks, WIP).
- Develop To‑Be scenarios to evaluate:
- Automation and closed‑loop control introduction
- MES/MOM enablement
- Scheduling and rule optimization
- Ensure the model clearly demonstrates quantified benefits across productivity, throughput, and inventory reduction.
3. Tooling & Architecture Alignment
- Evaluate and articulate the appropriate use of simulation vs. design tools, clearly distinguishing:
- Technomatics Plant Simulation for process flow and OEE analysis
- COMOS for P&ID, pipelines, and engineering documentation (non‑simulation use)
- Align simulation logic with the existing systems landscape, including:
- SAP PP/MM/QM/EWM
- OMP / OPR planning and scheduling tools
- SCADA / DCS / PLC layers
- Ensure simulation assumptions reflect real‑world system constraints and integration points.
4. Client Engagement & On‑Site Delivery
- Work on‑site at Customer's Manufacturing facility for an extended assessment and modeling phase (expected 4–5 weeks).
- Engage directly with plant operations, engineering, IT/OT, and planning stakeholders to:
- Validate process understanding
- Capture undocumented rules and tribal knowledge
- Review simulation outputs and scenarios
- Support executive‑level discussions by translating simulation outcomes into clear, decision‑ready insights.
Required Skills & Experience
Mandatory
- 8–12+ years of experience in manufacturing process simulation
- US Business Visa (B1)
- Hands‑on expertise with Siemens Tecnomatix Plant Simulation, including Fluid Library
- Proven experience modeling:
- Batch and process industries (blending, tanks, filling, fluid flows)
- Manual vs. automated manufacturing environments
- Strong understanding of:
- OEE, throughput analysis, bottleneck identification
- Manufacturing planning, scheduling, and execution logic
- Ability to translate ambiguous plant realities into structured simulation logic
Preferred
- Experience in chemical, oil & gas, or process manufacturing plants
- Exposure to SAP‑centric manufacturing landscapes (PP, QM, EWM, PM)
- Understanding of closed‑loop automation, MES/MOM concepts, and OT‑IT integration
- Prior on‑site assessment and consulting‑style engagements with manufacturing clients
Soft Skills & Mindset
- Practitioner mindset with strong problem‑structuring ability
- Comfortable operating in data‑poor, ambiguity‑rich environments
- Clear communicator able to engage plant engineers and senior leaders alike
- Collaborative approach aligned with cross‑functional and global teams
