Sr. Engineer (Mfg Engg - Simulation)

Why Work at Rehlko

Our work is guided by our purpose: creating an energy-resilient world for a better future. This purpose embodies the legacy we bring, with more than 100 years as the global leader in energy resilience, delivering solutions critical to sustain and improve life.

Our teams have the opportunity to provide a critical resource – energy – that ensures safety, security, and independence for people around the world. Our team members are focused on pushing boundaries, continuing to innovate in an ever-changing landscape, and keeping up with the pace required to create solutions for today’s world demands.

Our product range includes engines, generators, power conversion, UPS systems, EV components and electrification solutions, microgrid controls and management, and clean energy solutions that serve a broad spectrum of OEM, residential, industrial, and commercial customers. At Rehlko, you have the freedom to identify, create, and deliver solutions – large and small – that help people and communities thrive in the moments that matter.

At Rehlko, our team members are the essential energy that powers our organization’s success. We are committed to fostering a safe and sustainable work environment where safety is everyone’s responsibility. We empower every team member to actively participate in our Zero Is Possible safety culture by encouraging open communication, proactively reporting hazards, following protocols, and suggesting improvements. Join us in creating an energy resilient world for a better future!

What We Offer

At Rehlko, our Total Rewards programs are designed to accelerate growth, energize performance, and support a culture of inclusion at every stage of life and work. We offer total rewards that are easily understood, recognize results, enable career mobility, and reflect our commitment to valuing diverse needs in a fast-moving world. We provide:

Competitive compensation and benefits

Work-life flexibility

Recognition and rewards

Development and career opportunities

A safe and inclusive workplace

Why You Will Love this Job

POSITION DESCRIPTION –

Job title – Sr. Engineer – Mfg Engg - Simulation

Department – Operations

Reporting Manager – Deputy General Manager – Operations

Division/Location – Rehlko Services Center, Pune, Maharashtra, India

Role Overview

The Sr. Engineer – Manufacturing Engineering will be responsible for leading manufacturing system simulations, material flow analysis, and warehouse design using FlexSim or similar discrete-event simulation tools. The role requires strong analytical capability, the ability to interpret production system dynamics, and hands-on expertise in optimizing manufacturing & intralogistics processes.

Key Responsibilities

1. Simulation & Modelling

Develop detailed plant simulation models using FlexSim (or equivalent software) to analyze production scenarios, capacity, and throughput.

Validate simulation results with real-world data and provide actionable insights.

Conduct “what-if” analyses to evaluate process changes, layout modifications, and automation options.

2. Material Flow Analysis

Analyze material flow, handling systems, and equipment utilization to identify bottlenecks.

Design and optimize internal logistics, including material movement routes, storage strategies, and replenishment methods.

Recommend improvements in handling equipment, layout, and flow patterns.

3. Warehouse Design & Optimization

Develop warehouse layouts, racking designs, staging areas, and storage strategies in line with production requirements.

Evaluate storage systems, space utilization, and picking methods to improve efficiency.

Collaborate with cross-functional teams to implement warehouse improvements.

4. Manufacturing Process Engineering

Support the development and optimization of manufacturing processes and standard operating procedures (SOPs).

Contribute to capacity planning, line balancing, and takt-time analysis.

Conduct feasibility studies for process changes, automation, and new equipment.

5. Data Analysis & Reporting

Perform data-driven analysis using Excel, Power BI, or other analytical tools.

Prepare detailed reports, presentations, and recommendations for senior management.

Maintain documentation related to simulation models, layouts, and engineering changes.

6. Cross-functional Collaboration

Work closely with production, quality, maintenance, and supply chain teams for process improvement projects.

Participate in new product introduction (NPI) or new facility setup initiatives.

Support Kaizen, Lean Manufacturing, and continuous improvement activities.

QUALIFICATION & EXPERIENCE:

Bachelor’s degree in Mechanical / Industrial / Production Engineering (or equivalent).

5 to 7 years’ experience in Plant simulation, Material flow analysis, Warehouse design

Hands-on experience with FlexSim (mandatory) for discrete-event simulation.

Strong knowledge of material flow analysis, intralogistics, and warehouse design.

Good understanding of manufacturing layouts, line balancing, and industrial engineering concepts.

Proficiency in AutoCAD / DraftSight for layout creation & modification.

Strong analytical skills with experience in Excel, Power Query, Power BI, or statistical tools.

Behavioral Competencies

Strong problem-solving and analytical mindset.

Excellent communication and presentation skills.

Ability to manage multiple projects and timelines.

Collaborative working style with cross-functional teams

Key Performance Indicators (KPIs)

Improvement in throughput & cycle time from simulation outcomes.

Efficiency gains in material flow and warehouse operations.

Accuracy and effectiveness of simulation models & layout designs.

Successful implementation of engineering recommendations.

RELATIONSHIPS AND CONTACTS

Supervisory Relationships:

Reports to DGM - Operations

Organization Relationships:

Equivalent counterparts of business units.

Since the role include to support USA, Europe and APAC regions, the associate should have the flexibility to work in 2nd shifts that may range from 2:30 pm to 11:30 pm, to cover up to 1pm CT (subject to change).

About Us

Rehlko proudly offers a rich history steeped in creativity and commitment to our associates and communities, along with competitive benefits and compensation. Our Purpose - Creating an energy resilient world for a better future - and Values: Curiosity, Trust, Pace, and Excellence, are important cultural components that shape the way we work and relate to one another. Learn more about Rehlko at https://www.rehlko.com/who-we-are. In addition to the investment in your development, Rehlko offers a comprehensive package with competitive salaries and a range of additional benefits.

Our Values

Curiosity – Seek, learn, share

Trust – Go farther together

Pace – Focus to go faster

Excellence – Find the win every day