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 todays 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 organizations success. We are committed to fostering a safe and sustainable work environment where safety is everyones 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: Bachelors 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 .