Akbar Aj

BIW Process Simulation Engineer with 4 years of experience in robotic offline programming, BIW weld process simulation, and manufacturing process planning across high-volume automotive programmes. Specialist in Tecnomatix Process Simulate and DELMIA / 3DEXPERIENCE, with a proven record of delivering collision-free robotic paths, kinematic modelling, spot distribution, fixture validation, and multi-robot simulation for global OEM programmes including Renault, JLR, and General Motors. Experienced in supporting process planning from concept through to production readiness, collaborating with design, manufacturing, and automation teams to drive efficient, error-free line integration.

Simulation & Design Engineer - TATA Technologies

(2022-04 - 2024-08)

BIW Process Simulation | Process Planning | DELMIA / 3DEXPERIENCE | General Motors Programmes

• Led BIW robotic simulation and process planning activities using DELMIA and 3DEXPERIENCE, covering Equipment Simulation and Assembly Evaluation modules.
• Developed and validated robotic offline programmes (OLP) for FANUC and KUKA robots on complex automotive BIW assembly lines, ensuring collision-free paths and process compliance.
• Supported end-to-end process planning for General Motors programmes — from layout validation and fixture position finalisation to production readiness sign-off.
• Executed bin-picking and rack-picking simulations integrating FANUC vision camera, validating process sequences before shop-floor deployment.
• Applied basic Discrete Event Simulation (DES) techniques to analyse production flow and line throughput, feeding results back into the process planning cycle.
• Created and modified complex surface models and tooling geometry using CATIA Generative Shape Design to support simulation accuracy.
• Collaborated cross-functionally with design, manufacturing, and automation teams to optimise system integration and resolve process conflicts early.

Simulation Engineer - Geotools Robotics Automation Pvt. Ltd.

(2022-12 - 2024-08)

BIW Simulation | Tecnomatix Process Simulate | Renault & JLR Programmes

• Performed full BIW robotic simulation using Tecnomatix Process Simulate for welding, painting, pick & place, and object flow operations across live production environments.
• Modelled kinematics for fixtures, grippers, weld guns, and tool changers, enabling accurate digital validation of tooling behaviour before physical build.
• Created collision-free robotic paths and executed multi-robot simulations, resolving reach and interference issues at the virtual stage.
• Managed component library creation, equipment selection (robots, weld guns, tool changers), and simulation model configuration within Process Simulate.
• Validated 20 new BIW vehicle variants on the Renault Batilly live production line (62 existing variants), performing spot distribution and tool modification across the entire line.

Bachelor of Engineering - Mechanical Engineering - R.T.E Society Rural Engineering College, Hulkoti, Gadag (2020)

Diploma - Mechanical Engineering - Anjuman Polytechnic, Hubli (2017)