Simulation Test Engineer

Volto Consulting; Warren (MI); On-site; USD 90,000 - 120,000; Full time

Job summary

Volto Consulting is seeking a Virtual Commissioning, Emulation & Simulation Test Engineer in Warren, MI. This role focuses on validating production behavior via Emulate3D and PLC emulation, and on developing robust simulation test automation.

You will implement normal, boundary, negative, and abnormal test cases with fault injection, perform SIL/HIL validation and HMI testing, analyze results, and document defects for rapid resolution. Collaboration with multi-disciplinary teams is essential.

Qualifications

• Hands-on experience with virtual commissioning and emulation.
• Validation of production behavior using simulation and virtual I/O.
• Experience with SIL/HIL validation and HMI testing.
• Ability to develop reusable test scripts and automation.
• Good debugging, fault injection, and defect reporting skills.

Responsibilities

• Configure Emulate3D environments and PLC emulation for validation of production behavior.
• Create and maintain simulation test automation, scripts, and regression suites.
• Develop test cases (normal, boundary, negative, abnormal) including fault injection.
• Perform SIL/HIL validation and HMI testing for controls and interfaces.
• Analyze results, document defects, and verify corrective actions with retesting.
• Prepare validation reports with evidence, coverage and open issues.
• Collaborate with controls, automation, software, and manufacturing teams.
• Drive continuous improvement in model fidelity and testing efficiency.

Skills

Virtual commissioning

Emulation

Simulation

Test automation

Fault injection

SIL/HIL validation

HMI testing

Root-cause analysis

Cross-functional collaboration

Tools

Emulate3D

PLC emulation

Virtual I/O

Python

Version Control

CI/CD tools

CAD/3D models

Job description

Role: Virtual Commissioning, Emulation & Simulation Test Engineer

Location: Warren, MI 48092

Duration: 12 Months

100%On-Seat

Must Have Skills

• Strong understanding and hands‑on experience in virtual commissioning, emulation, simulation, production behavior validation, Emulate3D, PLC emulation, and virtual I/O
• Experience with SIL/HIL validation and HMI testing for controls, automation sequences, simulated equipment, and process states
• Experience developing simulation test automation, reusable scripts, regression suites, and normal, boundary, negative, and abnormal-condition test cases with fault injection
• Strong test analysis, debugging, troubleshooting, defect documentation, root‑cause analysis, corrective‑action verification, and validation‑reporting skills
• Effective communication and collaboration across controls, automation, software, manufacturing, engineering, IT, plant, supplier, and business teams

Roles & Responsibilities

• Configure Emulate3D virtual commissioning environments and integrate PLC emulation and virtual I/O to validate production behavior
• Create and maintain simulation test automation, reusable test scripts, regression suites, test data, and execution workflows
• Develop and execute normal, boundary, negative, and abnormal‑condition test cases for virtual systems, including fault- injection scenarios
• Perform SIL/HIL validation and HMI testing for controls, automation sequences, simulated equipment states, alarms, and system interfaces
• Analyze test results, investigate failures, document defects, support root‑cause analysis, and verify corrective actions through retesting
• Prepare validation reports with test evidence, coverage, deviations, open issues, and commissioning or release‑readiness recommendations
• Collaborate with controls, automation, software, manufacturing, engineering, IT, plant, supplier, and business teams
• Drive continuous improvement in model fidelity, test coverage, automation efficiency, validation quality, and deployment outcomes

Managerial Skills

• Strong analytical, debugging, troubleshooting, and problem‑solving skills
• Effective communication, cross‑functional collaboration, and stakeholder management
• Strong documentation, delivery coordination, corrective‑action follow‑through, and continuous‑improvement mindset

Key Words to search in Resume

Emulate3D, Virtual Commissioning, Emulation, Simulation, PLC Emulation, Virtual I/O, SIL/HIL, HMI Testing, Simulation Test Automation, Regression Testing, Fault Injection, Validation Reporting, Controls Integration, HMI/SCADA, Python, Version Control, Continuous Integration, CAD/3D Models, Robotics, Digital Twin, OT Cybersecurity, Manufacturing Engineering