Simulation Engineer

To support new product development (NPD) and production improvement activities by designing optimized casting processes, improving yield, reducing cost, and ensuring high-quality castings using simulation tools and best engineering practices.

Key Responsibilities

New Product Development (NPD) & Process Engineering

• Support development of high-quality castings with maximum yield and minimum lead time
  
• Work with Product, Process, and Project Management teams for customer approval of new development castings
  
• Revalidate NPD failure parts and close Foundry NPD Gate 7
  
• Revalidate production failure parts using MAGMASOFT simulation
  

Cost Reduction & Quality Improvement

• Identify high-cost items during PD process and initiate cost reduction actions
  
• Maintain Cost of Poor Quality (COPQ) within defined targets
  
• Identify high sand-to-metal ratio parts and bring them within target limits
  
• Improve low-yield castings through redesign and optimization of running and feeding systems
  

Simulation, Design & Engineering

• Perform casting simulation using MAGMASOFT for running and feeding system optimization
  
• Design and finalize gating, feeding, chills, cores, core boxes, and moulds
  
• Create 3D models for running and feeding systems
  
• Finalize pattern mounting and parting line designs
  
• Design moulding boxes and foundry accessories
  

Documentation & Quality Systems

• Prepare and maintain engineering documents and records (ISO, OHSAS, TQM)
  
• Ensure adherence to Business Excellence and TQM processes
  
• Participate in monthly inter-department audits and approve TQM status
  

Innovation & Cross-Functional Support

• Support Innovation and Automation Center in implementing new technologies in foundry NPD
  
• Identify and apply latest tools and technologies for product development
  
• Prepare drawings for Maintenance Department
  
• Develop and maintain PFMEA for NPD processes
  
• Conduct internal discussions and reviews for new product introductions
  

Key Skills & Competencies

Technical Skills

• Strong knowledge of foundry processes, casting design, and yield improvement
  
• Hands-on experience with MAGMASOFT or similar casting simulation software
  
• Proficiency in 3D modeling and engineering drawings
  
• Knowledge of PFMEA, quality systems, and NPD gates
  
• Understanding of ISO, OHSAS, TQM standards
  

Behavioral Skills

• Strong analytical and problem-solving skills
  
• Ability to work collaboratively with cross-functional teams
  
• Attention to detail and quality-focused mindset
  
• Cost-conscious and continuous improvement orientation
  

Preferred Qualifications

• BE / BTech / Diploma in Mechanical, Metallurgy, or Foundry Engineering
  
• Experience in foundry / casting manufacturing environment