Job
Description
Job Title: BIW (Body-In-White) Process & Simulation Engineer
Department: Manufacturing Engineering / Process Engineering / BIW
Reports To: BIW Manager / Manufacturing Engineering Lead
Job Summary: The BIW Process & Simulation Engineer is responsible for formability analysis, robotic welding simulation, process planning, and manufacturing feasibility for Body-In-White (BIW) subassemblies. The role requires expertise in CAE simulation tools like AutoForm/Pam-Stamp and robotic simulation platforms such as Process Simulate (PS) or Teamcenter. The candidate will contribute to ensuring defect-free manufacturing processes, validating robot paths, optimizing cycle time, and supporting the production ramp-up and post-SOP (Start of Production) activities.
Key Responsibilities: Formability & Feasibility: Perform formability analysis of sheet metal parts using CAE tools (AutoForm / Pam-Stamp).
Suggest countermeasures for defects such as wrinkles, splits, or thinning during forming.
Conduct manufacturing feasibility studies for new model introductions in existing production lines.
BIW Process Planning: Develop detailed BIW process plans for manual and robotic welding lines.
Create manufacturing process flows, line layouts, and cycle time charts for RFQ and execution.
Conduct process studies considering guns, fixtures, and equipment and recommend necessary product or process changes for manufacturability.
Robotic Simulation & Offline Programming (OLP):Develop robotic welding simulation cells using Process Simulate (PS) Teamcenter or standalone tools.
Build complete station/cell/line models by incorporating all relevant resources (robots, guns, fixtures).
Perform reachability analysis, create robot paths applying all kinematics, and ensure zero collisions with tools.
Generate basic paths for welding, tip dressing, etc., and define zoning conditions to avoid collision.
Use virtual controllers (ABB, Fanuc, KUKA) to generate accurate OLP with a cycle time accuracy of 99%.
Collaborate with line builders to validate and optimize robot paths and zoning and provide feedback for design improvements.
Standards & Documentation: Develop check sheets and standards for simulation and OLP based on benchmarking and lessons learned.
Cross-functional Collaboration: Work closely with CME process, PLC, and line builders for simulation verification during DAP (Design Approval Process) and supplier trials.
Support installation, commissioning, and post-SOP activities, ensuring process validation and cycle time adherence.
Ensure continuous involvement with the execution team to prevent errors, collisions, or production losses.
Root Cause Analysis & Optimization: Analyze and resolve bottlenecks to achieve target cycle times.
Drive process optimizations and continuous improvements.
Qualifications & Skills: Education: Bachelor’s degree in Mechanical, Production, Industrial, or Automotive Engineering.
Experience:4–8 years of experience in BIW process engineering, robotic simulation, and OLP.
Technical Skills: Hands-on experience with CAE tools like AutoForm, Pam-Stamp for formability analysis.
Proficiency in robotic simulation tools like Process Simulate (PS) Teamcenter or equivalent.
Knowledge of robotic programming and virtual controllers (ABB, Fanuc, KUKA, Yaskawa).
Strong understanding of BIW welding processes (manual and robotic).
Expertise in cycle time calculation, layout development, and process flow mapping.
Familiarity with RFQ preparation and technical documentation.
Soft Skills: Excellent problem-solving, analytical, and troubleshooting skills.
Strong communication and cross-functional collaboration abilities.
Attention to detail and commitment to zero-error execution.
Ability to work under tight deadlines and manage multiple projects.
Work Model: Onsite
