Our work is guided by our purpose: creating an energy-resilient world for a better future. This purpose embodies the legacy we bring, with more than 100 years as the global leader in energy resilience, delivering solutions critical to sustain and improve life.
Our teams have the opportunity to provide a critical resource – energy – that ensures safety, security, and independence for people around the world. Our team members are focused on pushing boundaries, continuing to innovate in an ever-changing landscape, and keeping up with the pace required to create solutions for today’s world demands.
Our product range includes engines, generators, power conversion, UPS systems, EV components and electrification solutions, microgrid controls and management, and clean energy solutions that serve a broad spectrum of OEM, residential, industrial, and commercial customers. At Rehlko, you have the freedom to identify, create, and deliver solutions – large and small – that help people and communities thrive in the moments that matter.
At Rehlko, our team members are the essential energy that powers our organization’s success. We are committed to fostering a safe and sustainable work environment where safety is everyone’s responsibility. We empower every team member to actively participate in our Zero Is Possible safety culture by encouraging open communication, proactively reporting hazards, following protocols, and suggesting improvements. Join us in creating an energy resilient world for a better future!
What We Offer
At Rehlko, our Total Rewards programs are designed to accelerate growth, energize performance, and support a culture of inclusion at every stage of life and work. We offer total rewards that are easily understood, recognize results, enable career mobility, and reflect our commitment to valuing diverse needs in a fast-moving world. We provide:
Competitive compensation and benefits
Work-life flexibility
Recognition and rewards
Development and career opportunities
A safe and inclusive workplace
Why You Will Love this Job
POSITION DESCRIPTION –
Job title –Sr. Engineer – Mfg Engg - Simulation
Department – Operations
Reporting Manager – Deputy General Manager – Operations
Division/Location – Rehlko Services Center, Pune, Maharashtra, India
Role Overview
The Sr. Engineer – Manufacturing Engineering will be responsible for leading manufacturing system simulations, material flow analysis, and warehouse design using FlexSim or similar discrete-event simulation tools. The role requires strong analytical capability, the ability to interpret production system dynamics, and hands-on expertise in optimizing manufacturing & intralogistics processes.
Key Responsibilities
1. Simulation & Modelling
Develop detailed plant simulation models using FlexSim (or equivalent software) to analyze production scenarios, capacity, and throughput.
Validate simulation results with real-world data and provide actionable insights.
Conduct “what-if” analyses to evaluate process changes, layout modifications, and automation options.
2. Material Flow Analysis
Analyze material flow, handling systems, and equipment utilization to identify bottlenecks.
Design and optimize internal logistics, including material movement routes, storage strategies, and replenishment methods.
Recommend improvements in handling equipment, layout, and flow patterns.
3. Warehouse Design & Optimization
Develop warehouse layouts, racking designs, staging areas, and storage strategies in line with production requirements.
Evaluate storage systems, space utilization, and picking methods to improve efficiency.
Collaborate with cross-functional teams to implement warehouse improvements.
4. Manufacturing Process Engineering
Support the development and optimization of manufacturing processes and standard operating procedures (SOPs).
Contribute to capacity planning, line balancing, and takt-time analysis.
Conduct feasibility studies for process changes, automation, and new equipment.
5. Data Analysis & Reporting
Perform data-driven analysis using Excel, Power BI, or other analytical tools.
Prepare detailed reports, presentations, and recommendations for senior management.
Maintain documentation related to simulation models, layouts, and engineering changes.
6. Cross-functional Collaboration
Work closely with production, quality, maintenance, and supply chain teams for process improvement projects.
Participate in new product introduction (NPI) or new facility setup initiatives.
Support Kaizen, Lean Manufacturing, and continuous improvement activities.
QUALIFICATION & EXPERIENCE:
Bachelor’s degree in Mechanical / Industrial / Production Engineering (or equivalent).
5 to 7 years’ experience in Plant simulation, Material flow analysis, Warehouse design
Hands-on experience with FlexSim (mandatory) for discrete-event simulation.
Strong knowledge of material flow analysis, intralogistics, and warehouse design.
Good understanding of manufacturing layouts, line balancing, and industrial engineering concepts.
Proficiency in AutoCAD / DraftSight for layout creation & modification.
Strong analytical skills with experience in Excel, Power Query, Power BI, or statistical tools.
Behavioral Competencies
Strong problem-solving and analytical mindset.
Excellent communication and presentation skills.
Ability to manage multiple projects and timelines.
Collaborative working style with cross-functional teams
Key Performance Indicators (KPIs)
Improvement in throughput & cycle time from simulation outcomes.
Efficiency gains in material flow and warehouse operations.
Accuracy and effectiveness of simulation models & layout designs.
Successful implementation of engineering recommendations.
RELATIONSHIPS AND CONTACTS
Supervisory Relationships:
· Reports to DGM - Operations
Organization Relationships:
· Equivalent counterparts of business units.
Since the role include to support USA, Europe and APAC regions, the associate should have the flexibility to work in 2nd shifts that may range from 2:30 pm to 11:30 pm, to cover up to 1pm CT (subject to change).
About Us
Rehlko proudly offers a rich history steeped in creativity and commitment to our associates and communities, along with competitive benefits and compensation. Our Purpose—Creating an energy resilient world for a better future—and Values: Curiosity, Trust, Pace, and Excellence, are important cultural components that shape the way we work and relate to one another. Learn more about Rehlko at https://www.rehlko.com/who-we-are. In addition to the investment in your development, Rehlko offers a comprehensive package with competitive salaries and a range of additional benefits.Rehlko is an equal opportunity employer that prohibits discrimination and will make decisions regarding employment opportunities, including, but not limited to, hiring, job assignment, compensation, promotion, benefits, training, discipline, and termination, promote equal opportunities in every aspect of our process.Our Values
Curiosity – Seek, learn, share
Trust – Go farther together
Pace – Focus to go faster
Excellence – Find the win every day
Skills Required
- Bachelor's degree in Mechanical, Industrial, or Production Engineering (or equivalent)
- 5 to 7 years' experience in plant simulation, material flow analysis, and warehouse design
- Hands-on experience with FlexSim (mandatory) for discrete-event simulation
- Strong knowledge of material flow analysis, intralogistics, and warehouse design
- Proficiency in AutoCAD or DraftSight for layout creation and modification
- Experience with Excel, Power Query, Power BI, or statistical analysis tools
- Good understanding of manufacturing layouts, line balancing, and industrial engineering concepts
- Strong problem-solving, communication, and presentation skills; ability to manage multiple projects
- Flexibility to work second-shift hours (approx. 2:30 pm to 11:30 pm) to support global regions
Rehlko Compensation & Benefits Highlights
The following summarizes recurring compensation and benefits themes identified from responses generated by popular LLMs to common candidate questions about Rehlko and has not been reviewed or approved by Rehlko.
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Fair & Transparent Compensation — Pay is considered fair-to-competitive across many roles, with professional tracks like project management, engineering leadership, and sales often aligning well with market levels. Role and geography differences are acknowledged but compensation is frequently characterized as good or competitive.
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Healthcare Strength — Health coverage is described as comprehensive and good value, including medical, dental, vision, mental‑health/EAP resources, and HSA‑compatible options. Cost and coverage are often portrayed as favorable in the U.S.
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Parental & Family Support — Paid parental leave provisions are emphasized for both birthing and non‑birthing parents. Additional family supports such as milk‑shipping services reinforce a family‑friendly offering.
Rehlko Insights
What We Do
Rehlko is a global leader in energy resilience, delivering the solutions critical to sustain and improve life. Formerly, for more than 100 years as Kohler Energy, our teams have excelled, reliably meeting today’s energy needs while planning for tomorrow’s. Now, with a new name and increased focus, we are giving our customers more control over where energy is sourced and where it goes, from industrial applications to your own backyard. Our solutions give people the resilience they need to keep building a brighter future, together. At Rehlko, we innovate relentlessly because we know we don’t just offer energy solutions – we are creating an energy resilient world for a better future. We provide worldwide solutions thanks to our regional locations in NA, EMEA, LATAM, APAC, and India. Learn more about our products: Power Systems North America: https://www.powersystems.rehlko.com Power Systems EMEA: https://www.powersystems.rehlko.com/emea Engines: https://www.engines.rehlko.com Rehlko’s affiliated brands include Kohler Home Energy, Kohler Uninterruptible Power, Curtis Instruments, and Clarke Energy.
