Simulation Engineer - Packaging and Digital Manufacturing

Engineer - Simulation, Packaging & Digital Manufacturing About Us: BW Design Group is a fully integrated architecture, engineering, construction, system integration, and consulting firm committed to helping our clients realize their most critical goals from Strategy to Commercialization. As the only firm born from a manufacturing technology company to become an independent and fully integrated firm, we combine deep domain expertise in the manufacturing environment with an approach that is built to serve the dynamic needs of our clients. Rooted in our distinct culture of Truly Human Leadership, we cultivate the leaders who will define tomorrow and partner with our clients in the food & beverage, life sciences, industrial, and advanced technology industries to build the future of manufacturing and technology. Barry-Wehmiller is a diversified global supplier of engineering consulting and manufacturing technology for the packaging, corrugating, sheeting and paper-converting industries. By blending people-centric leadership with disciplined operational strategies and purpose-driven growth, Barry-Wehmiller has become a $3 billion organization with nearly 12,000 team members united by a common belief: to use the power of business to build a better world. Job Description: Position Overview We are seeking a highly analytical and technically skilled Simulation Engineer with hands-on experience in 3D manufacturing and discrete-event simulation. Core strengths include experience with Emulate3D, FlexSim, or equivalent simulation software, C++ knowledge, and the ability to develop and validate models of production systems and material flow. High-speed packaging experience, particularly bottling and canning in the consumer-packaged goods (CPG) industry, is preferred—not required. Candidates are not expected to bring expertise across packaging, process, and warehouse operations; domain-specific knowledge can be developed with guidance from engineering and operations specialists. Warehouse simulation, controls, virtual commissioning, and 3D modeling or visualization experience are additional advantages, not prerequisites. The successful candidate will develop and validate simulation models, evaluate production-line performance, identify operational bottlenecks, and support packaging-system design and optimization through data-driven analysis. Warehouse simulation studies may be supported as needed, with guidance from warehouse operations specialists. Experience: 5+ years preferred Industry: Consumer Packaged Goods (CPG), Food & Beverage, Manufacturing, or Industrial Automation Key Responsibilities Simulation Modeling and Development Develop, configure, and validate 3D simulation models of manufacturing and packaging systems using Emulate3D, FlexSim, or equivalent simulation platforms; support warehouse models where applicable, with guidance as needed. Develop simulation logic, customized behaviors, and model components using C++ and the programming capabilities available within the selected simulation environment. Simulate production-line layouts, equipment interactions, material flow, conveyor systems, buffers, and equipment operating sequences. Perform scenario analysis to evaluate alternative line configurations, equipment capacities, operating strategies, and production rates. Debug, troubleshoot, and optimize simulation models to ensure accuracy and reliability. Where skills and project needs align, provide 3D modeling and visualization support, including creating or updating equipment models and layouts in Revit, Inventor, or equivalent tools. This is an optional supporting responsibility, not a core requirement. Manufacturing Analysis and Optimization Apply simulation and industrial engineering principles to design and optimize high-speed CPG packaging lines, including bottling/cans, filling, conveying, accumulation, labeling, packing, and palletizing. Collect and analyze process times, production rates, and downtime using Excel for data preparation, statistical analysis, performance calculations, and simulation-result analysis; use warehouse data for occasional studies with support from operations specialists. Assess throughput, cycle times, capacity, equipment and resource utilization, buffer capacity and occupancy, and line efficiency to identify bottlenecks and improve line balancing. Conduct what-if analyses of production scenarios, downtime, speed changes, demand variability, and operating conditions to evaluate performance and improvement opportunities. Collaborate with packaging, manufacturing, automation, and equipment-supplier teams to define process requirements and validate simulation assumptions. Translate simulation results into actionable recommendations for packaging-line design, capacity planning, and continuous improvement through structured problem-solving and data-driven decision-making. Where applicable, support equipment-sequence and material-handling interface modeling and virtual commissioning for packaging and automated warehouse systems with guidance from controls engineers. Prior controls or virtual commissioning experience is desired, not required; controls design and PLC programming expertise are not required. Core Requirements Bachelor’s degree in industrial, Mechanical, Manufacturing, or Electrical Engineering, Mechatronics, or a related field. Hands-on experience with Rockwell Emulate3D, FlexSim, or equivalent 3D manufacturing and discrete-event simulation software. Working knowledge of C++ (Flexscript) to develop or modify simulation logic and model behavior. Manufacturing or industrial engineering experience. Foundational understanding of production systems, material flow, and equipment interactions, with a willingness to learn packaging-, process-, and warehouse-specific applications. Knowledge of line balancing, cycle times, bottlenecks, and capacity planning. Strong analytical, quantitative, and problem-solving skills. Proficiency in Excel for data analysis and performance reporting. Strong communication and collaboration skills across engineering, operations, and automation teams. Preferred Requirements These skills are optional advantages, not prerequisites: Familiarity with PLC controls; exposure to automation using Rockwell Studio 5000 is a plus. Familiarity with warehouse operations or simulation, including storage, picking, and material flow. Key Success Criteria Develop and validate reliable simulation models of manufacturing and packaging systems. Apply programming skills to implement and troubleshoot simulation logic. Evaluate packaging-line performance and identify throughput constraints. Collaborate with packaging and manufacturing teams to improve system performance, involving warehouse operations, supply chain, and controls engineers as needed. Deliver clear, data-driven recommendations that support packaging-line design, capacity planning, and operational efficiency; contribute to warehouse studies with guidance when applicable. Nice to have: Support 3D modeling and visualization by creating or updating equipment models and layouts using Revit, Inventor, or equivalent tools, where skills and project needs align. This is an additional capability, not a required success criterion. #LI-SE1 At Barry-Wehmiller we recognize that people come with a wealth of experience and talent beyond just the technical requirements of a job. If your experience is close to what you see listed here, please still consider applying. We know that our differences often can bring about innovation, excellence and meaningful work—therefore, people from all backgrounds are encouraged to apply to our positions. Please let us know if you require reasonable accommodations during the interview process. ​ Company: Design Group