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Process Simulation Jobs in Warren, MI (NOW HIRING)

Dicastal North America

Process Engineer

Livonia, MI · On-site

The primary focus of this role is casting simulation, trial validation, and process optimization, while also supporting downstream machining and assembly operations to ensure seamless product ...

Stellantis

Virtual Assembly Lead

Auburn Hills, MI

$97K - $127K/yr

The Virtual Assembly Lead is responsible for coordinating and executing virtual assembly simulations and virtual builds that analyze automotive assembly processes to assist in scroll development ...

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All JobsProcess Simulation JobsProcess Simulation Jobs in Warren, MI

Process Simulation information

See Warren, MI salary details

$36.6K

$115.9K

$178.9K

How much do process simulation jobs pay per year?

As of Jun 23, 2026, the average yearly pay for process simulation in Warren, MI is $115,901.00, according to ZipRecruiter salary data. Most workers in this role earn between $86,400.00 and $137,600.00 per year, depending on experience, location, and employer.

What are the key skills and qualifications needed to thrive in the Process Simulation position, and why are they important?

To thrive in Process Simulation, a strong background in chemical engineering, process modeling, and analytical thinking is essential, often supported by a degree in engineering or a related field. Expertise with simulation software such as Aspen HYSYS, CHEMCAD, or MATLAB, and familiarity with process control systems, are highly valued, along with relevant certifications. Effective communication, problem-solving, and collaboration skills help professionals convey complex concepts and work efficiently with multidisciplinary teams. These qualifications are crucial for creating accurate process models, optimizing operations, and supporting evidence-based decision-making in industrial environments.

What does a typical day look like for someone working in Process Simulation?

A typical day in Process Simulation often involves developing, testing, and refining process models to optimize manufacturing or chemical processes. You’ll collaborate with engineers, plant operators, and project managers to gather data, validate simulations, and ensure alignment with production goals. Regular responsibilities may include running simulations on specialized software, analyzing results, and presenting findings and recommendations to stakeholders. The role tends to balance independent analytical tasks with team-oriented problem-solving, providing both technical challenges and opportunities for cross-functional communication.

What is a Process Simulation job?

A Process Simulation job involves using software tools to model, analyze, and optimize industrial processes in industries like chemical, manufacturing, and energy. Engineers in this role create virtual models to test different scenarios, improve efficiency, reduce costs, and ensure safety. They work with simulation software such as Aspen Plus, HYSYS, or MATLAB to predict system performance before physical implementation. This helps companies make data-driven decisions and improve overall process reliability.

What job categories do people searching Process Simulation jobs in Warren, MI look for? The top searched job categories for Process Simulation jobs in Warren, MI are:
What cities near Warren, MI are hiring for Process Simulation jobs? Cities near Warren, MI with the most Process Simulation job openings:
Process Simulation jobs near you
Infographic showing various Process Simulation job openings in Warren, MI as of June 2026, with employment types broken down into 79% Full Time, and 21% Temporary. Highlights an 100% In-person job distribution, with an average salary of $115,901 per year, or $55.7 per hour.
Process Design Engineer

Process Design Engineer

ALTEN Technology USA

Detroit, MI

Full-time

Posted 12 days ago

Job description

We're ALTEN Technology USA, an engineering company helping clients bring groundbreaking ideas to life-from advancing space exploration and life-saving medical devices to building autonomous electric vehicles. With 3,000+ experts across North America, we partner with leading companies in aerospace, medical devices, robotics, automotive, commercial vehicles, EVs, rail, and more.
As part of the global ALTEN Group-57,000+ engineers in 30 countries-we deliver across the entire product development cycle, from consulting to full project outsourcing.
When you join ALTEN Technology USA, you'll collaborate on some of the world's toughest engineering challenges, supported by mentorship, career growth opportunities, and comprehensive benefits. We take pride in fostering a culture where employees feel valued, supported, and inspired to grow.
Position Summary:
  • Client is looking for a Process Design Engineer to support automation and lean manufacturing for our business.
  • This position will play a crucial role in driving operational excellence, process optimization, and innovation in our manufacturing processes.
  • Responsible for developing and implementing advanced manufacturing strategies, leading cross-functional teams, and driving continuous improvement initiatives.
  • The ideal candidate will bring deep expertise in Power product manufacturing processes and proven ability to deliver continuous improvement in a dynamic, international environment.

Responsibilities:
  • Lead the New product process design, develop, and implement manufacturing processes for power products, including UPS systems, DC power supplies, (Future include also Thermal product) and related components, from prototype to full-scale production.
  • Conduct process simulations, feasibility studies, and risk assessments to optimize production workflows, reduce cycle times, and improve overall equipment effectiveness (OEE).
  • Apply DFM/DFA methodologies to review product designs, identify potential manufacturing issues early in the development cycle, and recommend modifications for ease of assembly, cost reduction, and quality enhancement.
  • Collaborate with design engineers to ensure new power product designs are manufacturable, incorporating feedback on materials, tolerances, and assembly techniques.
  • Lead root cause analysis for production issues, implementing corrective actions and preventive measures using tools like FMEA (Failure Mode and Effects Analysis) and Six Sigma.
  • Develop and maintain process documentation, including standard operating procedures (SOPs), work instructions, and process flow diagrams.
  • Oversee the selection, installation, and validation of manufacturing equipment and tooling specific to power electronics assembly, such as soldering, PCB fabrication, and enclosure assembly.
  • Monitor and analyze production metrics to identify opportunities for process improvements, cost savings, and waste reduction.
  • Ensure compliance with industry standards, safety regulations, and quality certifications (e.g., ISO 9001, UL for power products).
  • Mentor junior engineers and production staff on best practices in manufacturing processes and DFM/DFA.

Skills:
  • Proficient in executive communication and presentation.
  • Familiarity with ERP systems (e.g., SAP) and manufacturing execution systems (MES).
  • Experience in high-volume production environments for power products in Asia-Pacific regions.
  • Knowledge of sustainability practices in manufacturing, such as eco-friendly materials and energy-efficient processes.

Education and Certifications:
  • Bachelor's degree in mechanical engineering, Electrical Engineering, Manufacturing Engineering, or a related field; master's degree preferred.
  • Minimum of 5 + years of hands-on experience in manufacturing process design for power products, specifically UPS, DC power systems, or similar electronics.
  • Extensive expertise in DFM/DFA demonstrated success in applying these principles to reduce manufacturing costs and improve product reliability.
  • Strong knowledge of power electronics manufacturing techniques, including PCB assembly, thermal management, component sourcing, and testing protocols.
  • Proficiency in CAD software (e.g., SolidWorks, AutoCAD) for process design and simulation tools (e.g., Arena, FlexSim).
  • Experience with lean manufacturing principles, Kaizen events, and continuous improvement methodologies.
  • Excellent problem-solving skills, with the ability to analyze complex data and make data-driven decisions.
  • Strong communication and teamwork abilities to work effectively in a multicultural, cross-functional environment.

All qualified applicants will receive consideration for employment and will not be discriminated against on the basis of race, color, religion, sex, sexual orientation, gender identity, national origin, disability, protected veteran status, age, genetic information, or pregnancy.
Please beware of job seeker scams and see this important notice on our careers page for more information about our recruiting process.
Compliance Notice: Alten USA is a federal contractor subject to the requirements of the Vietnam Era Veterans' Readjustment Assistance Act (VEVRAA) and Executive Order 11246. We are an Equal Opportunity Employer and consider all qualified applicants without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or veteran status.
Drug Screening Requirement: As a federal contractor, Alten USA maintains a drug-free workplace. All candidates selected for employment will be required to successfully complete a pre-employment drug screening as a condition of hire.

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