AME Simulation Engineer

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OVERALL PURPOSE OF THE JOB

As part of the EU & Africa JIT and Structures AME team, this role is to support the Digital Twin strategy for these business groups. There is a 7-level approach to adopting Digital Twin tools. This role is specifically focused on levels 5 with close collaboration of 1st,, 3rd and 4th level.  

As a base for the 3D model creation, data (point clouds) will be used from Level 1 – Passive Visualization.

On Level 5 – Virtual Commissioning – virtual build of machine, equipment, production system by Geometry based models in order to simulation of process and defining base for future PLC program. DFA & DFAA assessments including slow builds. Verification of simulations provided by integrators(suppliers of equipment).

Level 3 – 3D Layout planning – with the task to create digital models for 3D layout planning with all active production & logistics processes (allowing Plant Teams to simulate various scenarios), create models of awarded projects (to minimize capital investment) and create models of RFQ projects to safely drive capital and labor reductions to ensure we are providing as competitive quotes to our Customers as possible. In addition to this, the models created will be used in the Discrete Event Simulation (level 4).

Level 4 – Discrete Event Simulation – is the primary focus, with the task to create digital models of all active production processes, (allowing Plant Teams to simulate various scenarios), create models of awarded projects (to minimize capital investment) and create models of RFQ projects to safely drive capital and labor reductions to ensure we are providing as competitive quotes to our Customers as possible. In addition to this, the models created will be used in the Virtual Commissioning of all equipment (level 5).

These digital twins will be used in all decision making, reducing risk of customer impact, maximizing value from capital investment and identifying cost saving opportunities together with impact on employee engagement by minimizing learning curve.

This role will be responsible for sharing lessons learned & best practices out of simulations including spreading culture of “digitalization” within Lear. This role will also need to support the other strategic Digital Twin initiatives as required by the Digital Twin Lead.

The role will be part of the AME – Digital Twin team.

Key Responsibilities

As a member of the EU&AF AME team, working with all stakeholders in the creation and deployment of digital twin models to maximize the benefit to Lear for capital expenditure and labor, whilst understanding risk of Customer impact.

•              Virtual Commissioning: Working with the rest of the Digital Twin team and with the rest of AME, particularly the Controls team, to;-

-              Create the Geometry based models of machine/equipment to verify the feasibility of defined process for different aspects as reachability of robots, Cycle time…

-              Geometry based models for DFA, DFAA assessment including slow builds and ergonomics

-              Create Models for future processes to combine with PLC code (using SIMMIT and PLC Sim Advance) to assess PLC programs for equipment prior to installation.

•              Discrete Event Simulation: - Working with the rest of the Digital Twin team and with the rest of AME to;

-              Define all Standards for using Technomatix Plant Simulation (or future Lear Standard softwares) to create processes, including creation of a library of process blocks, standard coding protocols, etc.

-              Create working models for all processes in all Plants to allow local simulations to be run with key variable changes by the Plant team to all decision making, reducing risk to of customer impact, maximizing value from capital investment and identifying cost saving opportunities. Simulations is enabling Plants to make decisions with best possible understanding of the outcomes.

-              Create working models for all processes for all awarded projects to allow local simulations to be run with key variable changes by the AME and Plant IE teams, to confirm capital requirements, ensuring Lear maximizing the value from capital expenditure.

-              Where time allows, create working models for anticipated processes for project RFQs to allow local simulations to be run with key variable changes by the AME and Plant IE teams, to ensure competitive quotations

-              Ensure standard data requirements are defined for all modelling requests and all outputs from the simulations are clearly noted, including the benefit to Lear.

-              Refining of models based on comparison to physical twin results with same inputs.

-              As required, support material flow modelling activities using the associated software within Lear.

-              Presentation of outputs internally within Lear, when requested.

•              3D Layout Planning: Working with the rest of the Digital Twin team and with the rest of AME, to;-

-              Create 3D models from 3D Point cloud data for current installations.

-              Using 3D models, create accurate 3d plant layouts for layout planning activities.

-              Participate in layout planning workshops on-site, with key Plant stakeholders and AME plant support.

-              Participate in optimization workshops on-site, with key Plant stakeholders and AME plant support.

-              Train Plant key users for usage 3D layout planning SW 

•              sharing lessons learned & best practices out of simulations including spreading culture of “digitalization” within Lear.

•              In addition to these tasks, other tasks, projects and responsibilities may be individually defined

Key Requirements

·        English language at a good level.

·        Discrete Event Simulation software training & experience

·        Basic understanding of coding.

·        3D layout simulation software training & experience

·        Strong problem-solving skills.

·        Good communicator – comfortable in presenting to all levels within the business.

·        Fully self-motivated

·        Good working knowledge of MS Office.