Virtual Build Simulation Engineer

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At Tata Technologies we make product development dreams a reality by designing, engineering and validating the products of tomorrow for the world’s leading manufacturers.
Due to our continued growth we are now recruiting for a Virtual Build Simulation Engineer to be based at our customers site in Crewe.

Our Engineering Research and Development department (ER&D) is a fast-growing function within Tata Technologies Limited that is assembled to work on exciting projects globally for multiple customers. It comprises highly specialized engineers across Automotive, Aerospace and Industrial Heavy Machinery.

As a Virtual Build Engineer, the role focuses on proactively validating both product design and assembly processes ahead of the design release milestone. Through advanced simulation techniques, the position aims to identify and resolve potential design and manufacturing issues early in the development cycle. The insights gained from virtual builds are used to demonstrate assembly feasibility and support customer making informed decisions regarding design modifications, ensuring a seamless transition from concept to production.

This position requires a full-time onsite presence at the customer’s location in Crewe, UK, five days a week.

The role focuses on validating product design and assembly processes through virtual builds prior to design release, enabling early detection and resolution of design and manufacturing issues. It involves cross-functional collaboration to ensure assembly feasibility and supports informed decision-making for potential design changes. The position integrates ergonomics, tooling analysis, and process simulation to optimize vehicle development.

• Utilize advanced simulation tools to evaluate, validate, and optimize product, process, and tooling designs, driving cost reduction and complexity minimization.
• Conduct dynamic simulation studies to assess manufacturing feasibility under various load cases.
• Analyze tool designs and their interface with product components to ensure seamless integration and manufacturability.
• Identify opportunities for design and process optimization, delivering detailed simulation reports to Manufacturing Engineers (MEs), Component Manufacturing Engineers (CMEs), and Tooling Integration Engineers (TIEs).
• Perform ergonomic assessments including reachability, hand access, and line-of-sight studies to support CMEs and Ergonomists.
• Collaborate with ergonomics teams to incorporate ergonomic postures into virtual build sequences.
• Lead virtual build activities across key milestones in the Global Vehicle Development Process.
• Develop and maintain comprehensive virtual build sequences tailored to plant-specific and program-specific requirements.
• Facilitate virtual build reviews with cross-functional teams including product design, manufacturing, and plant personnel.
• Integrate plant layouts and process documentation into virtual builds and simulation studies.
• Analyze all new parts within the release window to ensure manufacturability and process compatibility.
• Generate and validate configured Bill of Materials (BoM) for complete vehicle builds within Process Simulate.
• Maintain and execute virtual build checklists for each part number in its assembly context.
• Validate manufacturing assembly sequences specific to product and project requirements.
• Maintain detailed reports and KPI dashboards relevant to virtual analysis activities.
• Work closely with Feasibility and Design for Manufacturing (DFM) engineers at manufacturing plants to resolve identified issues.
• Support customer teams by addressing concerns raised during virtual build reviews and providing actionable solutions.

• Strong knowledge of general Assembly processes, tooling and equipment.
• Strong understanding of virtual manufacturing tools such as Process Simulate, Teamcenter, and CAD systems.
• Experience in product and process validation, including simulation-based analysis of tooling, ergonomics, and assembly feasibility.
• Familiarity with vehicle development processes, particularly around design release and…