Virtual Commissioning Engineer

Sarla Advantech; Pune District; On-site; INR 900,000 - 1,500,000; Full time

Job summary

Sarla Advantech in Pune is seeking an Engineer - Virtual Commissioning / Digital Twin to design and maintain digital twin simulations that mirror BIW production lines. You will enable virtual commissioning and data-driven decision-making through high-fidelity models.

You will collaborate with PLC programmers, robotics engineers, and safety experts to integrate twins into commissioning workflows, validate models with real data, and deliver clear stakeholder reports.

Qualifications

• Experience in designing, developing, and maintaining digital twin simulations for manufacturing.
• Ability to mirror complex systems and BIW production lines in digital models.
• Familiarity with virtual commissioning, data-driven decision making, and system optimization.

Responsibilities

• Create and maintain digital twin simulations to mirror complex systems and BIW production lines.
• Integrate data from PLCs, robots, sensors, IoT devices, and historical records for accurate digital representations.
• Build machine and line models, validate against performance data for accuracy and reliability.
• Execute simulations to test PLC and robot programs under various conditions and analyze outputs for optimization.
• Collaborate with PLC programmers, robotic engineers, and safety experts to integrate twins into workflows.
• Document simulation processes, assumptions, and results; prepare reports for stakeholders.
• Identify and implement improvements to increase simulation accuracy and efficiency.

Skills

Digital Twin

System Integration

Modelling & Validation

Simulation Execution

Collaborative Engineering

Documentation

Innovation & CI

Tools

RF Suite/Emulate 3D/ Delmia /Process Simulate

OPC/PLC Sim Advance

TIA Portal

Allen-Bradley Studio 5000

WinMOD

Kepware

Job description

Hello,

Greetings from Sarla Advantech! We are recruiting for the opportunity for . Engineer -Virtual Commissioning / Digital Twin

Position Overview

As a member of a newly established Digital Engineering team, you will be responsible for designing, developing, and maintaining digital twin simulations that accurately replicate physical machines, manufacturing lines, and processes. Your work will directly support virtual commissioning, system optimization, and data-driven decision-making. You will collaborate with multidisciplinary teams including PLC programmers, simulation engineers, and robotic specialists to ensure high-fidelity digital models and seamless integration across systems.

Key Responsibilities

• Digital Twin Development:
  Create and maintain digital twin simulations to mirror complex systems and manufacturing processes, with a focus on Body-in-White (BIW) production lines.
• System Integration:
  Integrate and synchronize data from various sources (PLCs, robots, sensors, IoT devices, historical records) to ensure a comprehensive and accurate digital representation of physical assets.
• Modelling & Validation:
  Build machine and line-level models to simulate real-world behaviour and component interactions. Validate these models against actual performance data to ensure accuracy and reliability.
• Simulation Execution & Analysis:
  Execute simulations using industry-standard tools to test PLC and robot programs under various conditions. Analyse outputs such as cycle time and machine behaviour to support performance optimization.
• Collaborative Engineering:
  Work in close coordination with PLC programmers, robotic simulation engineers, and machine safety experts to integrate digital twins into commissioning workflows and production planning.
• Documentation & Reporting:
  Document all simulation processes, assumptions, and results. Create clear reports and presentations to communicate technical insights and recommendations to stakeholders.
• Innovation & Continuous Improvement:
  Stay abreast of the latest advancements in digital twin technology, simulation software, and virtual commissioning tools. Identify and implement process enhancements to improve simulation accuracy and efficiency.

Technical Skills & Experience

• Proficiency in systems modelling, control theory, and simulation techniques, especially within RF Suite/Emulate 3D/ Delmia /Process Simulate (including Line Simulation, Flow Simulation, Logic Blocks, Smart Objects, Signal Mapping).
• Ability to develop Logic Blocks and CEE components in Process Simulate.
• Experience in closed-loop simulation using CEE with soft PLCs.
• Hands-on knowledge of hardware-in-the-loop (HIL) and software-in-the-loop (SIL) PLC logic testing.
• Familiarity with OPC/PLC Sim Advance, TIA Portal, and Allen-Bradley Studio 5000.
• Knowledge in PLC programming (Siemens, Rockwell, Mitsubishi), along with familiarity with simulation and connectivity tools such as WinMOD and Kepware, will be considered an added advantage.