Body Construction Engineering Manager - Process Simulation and Virtual Commissioning

Ford Motor; Chennai; On-site; INR 4,000,000 - 7,000,000; Full time

Job summary

Ford Motor in Chennai seeks a Senior Body Construction Engineering Manager to lead a high‑performing BIW engineering team focused on process simulation and virtual commissioning. You will guide digital manufacturing capabilities, establish standards, and collaborate with Manufacturing IT, Controls Engineering, Product Development, and suppliers to improve production readiness and reduce risk.

Requirements include 7+ years in BIW manufacturing, 3+ years in digital manufacturing and virtual

Qualifications

• Bachelor's degree in Mechanical or Manufacturing Engineering or related field.
• 7+ years in automotive BIW manufacturing, process engineering, and ramp-up activities.
• 3+ years in digital manufacturing, process simulation, robotics validation.
• 3+ years in virtual commissioning; leadership experience.

Responsibilities

• Lead and develop a BIW process simulation team across manufacturing engineering activities.
• Define team structure, standards, processes, deliverables, and performance.
• Mentor engineers, contractors, and suppliers; manage resources and budgets.
• Drive automation and digital transformation within BIW programs.

Skills

Team leadership

Process simulation

Robotics validation

Analytical skills

Stakeholder management

Education

Bachelor's degree in Mechanical Engineering

Manufacturing Engineering

Tools

Siemens Process Simulate

Tecnomatix

Job description

Body Construction Engineering Manager – Process Simulation & Virtual Commissioning

The Body Construction Engineering Manager – Process Simulation & Virtual Commissioning is responsible for leading and developing a high-performing engineering team supporting Body-in-White (BIW) manufacturing operations through advanced digital manufacturing technologies. This role provides both technical and people leadership across process simulation, robotics validation, virtual commissioning, automation, and digital transformation initiatives. The position works closely with Manufacturing Engineering, Controls Engineering, Product Development, Manufacturing IT, suppliers, and plant operations teams to identify manufacturing risks early, optimize manufacturing processes, and improve production readiness prior to equipment installation and production launch. The successful candidate will play a key role in advancing digital manufacturing capabilities, improving engineering efficiency, and establishing simulation and virtual commissioning standards across multiple automotive manufacturing programs and facilities.

Team Leadership & Capability Development

• Build, lead, and develop a Body Process Simulation team supporting BIW manufacturing engineering activities.
• Define team structure, technical responsibilities, engineering standards, work processes, deliverables, and performance expectations.
• Lead, mentor, and coordinate a multidisciplinary team of engineers, simulation specialists, controls engineers, contractors, and supplier resources.
• Recruit, develop, and retain technical talent in process simulation, robotics, offline programming, virtual commissioning, automation, and digital manufacturing technologies.
• Establish competency frameworks, mentoring programs, training plans, and career development pathways.
• Manage resource planning, project workloads, budgets, supplier support, and delivery performance across multiple manufacturing programs and locations.
• Foster a culture focused on safety, collaboration, innovation, quality, continuous improvement, and standardization.

Process Simulation & Digital Manufacturing

• Lead the application of Siemens Process Simulate, Tecnomatix, or similar digital manufacturing tools to validate body shop manufacturing processes prior to equipment installation.
• Establish standard methodologies for: Robot reach and accessibility studies Collision detection and avoidance Cycle time validation Tooling and weld gun accessibility validation Ergonomic assessments Robot path optimization Station layout verification.
• Ensure simulation activities support manufacturing feasibility reviews, equipment design validation, tooling development, and process planning.
• Develop and maintain simulation models, robot libraries, tooling standards, process libraries, work instructions, and best practices.
• Improve simulation quality, model accuracy, data management practices, and process validation efficiency.
• Identify and communicate manufacturing risks, design concerns, capacity constraints, automation challenges, and process issues early during program development.

Virtual Commissioning

• Develop organizational capability in virtual commissioning technologies and methodologies.
• Lead validation of robot sequences, programmable logic controller (PLC) logic, safety interlocks, equipment interfaces, and automated manufacturing processes in a virtual environment.
• Define virtual commissioning standards, test procedures, acceptance criteria, and deployment methodologies.
• Collaborate with Controls Engineering, equipment suppliers, and plant teams to ensure an effective transition from virtual to physical commissioning.
• Support issue resolution related to robotics, controls, automation systems, simulation models, commissioning activities, and production support.

Automation & Digital Transformation

• Drive automation and digital manufacturing initiatives to improve simulation efficiency, engineering productivity, and manufacturing validation processes.
• Identify opportunities to automate model creation, reporting, data validation, engineering analysis, and repetitive simulation activities.
• Support the adoption of advanced digital tools, data analytics, digital twins, and AI-enabled engineering solutions to improve: Engineering productivity Manufacturing risk identification Root-cause analysis Knowledge management Decision support.
• Partner with Manufacturing IT, Controls Engineering, Product Development, and Data & Analytics teams to evaluate and implement scalable digital manufacturing solutions.

Required Qualifications

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, or a related technical discipline.
• Minimum 7+ years of experience in automotive Body-in-White manufacturing, process engineering, manufacturing launches, equipment installation, commissioning, production trials, and ramp-up activities.
• Minimum 3+ years of experience in digital manufacturing, process simulation, robotics validation.
• Minimum 3+ years of experience in Virtual commissioning.
• Proven experience leading and developing engineering teams and coordinating supplier and contractor resources.
• Hands-on experience with Siemens Process Simulate, Tecnomatix, or equivalent manufacturing simulation platforms.
• Strong knowledge of body shop robotics, tooling, fixtures, automated manufacturing cells, and material handling systems.
• Working knowledge of industrial controls, PLC architecture, automation sequencing, robot-controls integration, and virtual commissioning principles.
• Knowledge of BIW joining technologies, including resistance spot welding, arc welding, laser welding, adhesive bonding, riveting, clinching, or related manufacturing processes.
• Strong analytical, problem-solving, communication, and stakeholder management skills.

Preferred Qualifications

• Experience supporting multiple automotive OEM manufacturing environments.
• Advanced experience in offline robot programming and virtual commissioning.
• Exposure to AI-enabled engineering tools, digital twin technologies, or manufacturing analytics solutions.
• Knowledge of Geometric Dimensioning and Tolerancing (GD&T), Advanced Product Quality Planning (APQP), Production Part Approval Process (PPAP), Process Failure Mode and Effects Analysis (PFMEA), Control Plans, and structured problem-solving methodologies.
• Experience leading large, cross-functional engineering teams across multiple manufacturing locations.

Experience Level Senior Level