Senior Prototype Assembly Technician

BorgWarner•Auburn Hills, MI

About The Position

The Senior Prototype Assembly Technician supports prototype operations by inspecting, preparing, assembling, processing, and troubleshooting components and assemblies. The role builds prototype components, subassemblies, and assemblies to engineering specifications, performs in-process dimensional checks, and maintains inventory, traceability, and build records for prototype programs and engineering evaluations. The technician works from engineering drawings, bills of material, specifications, work instructions, process-flow information, and project requirements. Work includes manual assembly operations and use of shop equipment, assembly fixtures, hand and power tools, and dimensional inspection instruments. The position also supports prototype receiving, inventory control, reject evaluation and rebuilds, documentation, serialization, packing, shipment preparation, and coordination with engineering, quality, manufacturing, inspection, tool-room, shipping, production, and supplier contacts. The role is based in Prototype Operations in Ithaca, New York. It requires following applicable safety, training, housekeeping, chemical-handling, material-handling, and personal protective equipment requirements. BorgWarner states that it provides equal employment opportunity in accordance with applicable law.

Requirements

High school diploma or equivalent is required.
At least five years of practical experience supporting prototype component and assembly operations, including assembly, inspection, fabrication, processing, or troubleshooting.
Demonstrated mechanical ability and aptitude, including safe use of hand tools, power tools, presses, riveters, and general prototype-shop equipment.
Ability to read and understand engineering drawings, specifications, bills of material, and process-flow documentation.
Ability to use conventional dimensional inspection equipment and apply decimals, fractions, and basic arithmetic.
Ability to follow work instructions, procedures, routing sheets, job safety analyses, and established prototype processing requirements.
Ability to learn and safely operate role-specific assembly, marking, material-handling, inspection, and packaging equipment through formal and on-the-job training.
Ability to enter, retrieve, and review project, inspection, quality, and inventory data using company computer systems and Microsoft Office applications.
Strong problem-solving and troubleshooting skills, including the ability to make sound decisions with limited information.
Professional interpersonal communication skills and ability to coordinate effectively with engineering, quality, manufacturing, production, tool-room, inspection, shipping, and supplier contacts.

Nice To Haves

Associate degree or two years of technical training.
Working knowledge of prototype receiving, stock control, pick-list processing, packing, labeling, shipping preparation, quarantine, traceability, and record-retention practices.

Responsibilities

Select, identify, and inspect prototype parts against engineering drawings, bills of material, specifications, and project requirements before assembly.
Assemble prototype components, subassemblies, and assemblies using engineering prints, work instructions, process-flow information, and direction from Prototype supervision or engineering.
Perform fit-up, alignment, fastening, pressing, riveting, staking, pre-stressing, scribing, and other manual assembly operations.
Operate approved shop equipment and hand tools, including drill presses, arbor presses, bench grinders, parts washers, riveters, and pre-stress machines.
Set up and operate torque drivers and meters, seating and rivet stations, prestress equipment, marking and serialization equipment, scales, gages, indicators, and approved assembly fixtures.
Verify fixture condition and readiness before use, and maintain organized storage of fixtures, tooling, and measurement equipment.
Make minor component modifications from drawings or other approved graphic information using common and specialized hand and power tools.
Use dimensional inspection tools to verify component and assembly requirements.
Identify and document assembly or dimensional concerns, and work with Product, Manufacturing, and Quality Engineering to resolve issues affecting prototype builds.
Hand assemble, pre-stress, measure, and scribe HyVo, roller, bush, and inverted-tooth (Silent) chains.
Hand assemble timing-drive products, including tensioners, arms, guides, hVCTs, and eVCTs.
Process and support prototype arms, guides, sprockets, mechanical and hydraulic tensioners, center bolts, solenoids, check valves, pressure-relief valves, timing chains, and VCT phaser units according to applicable instructions and project requirements.
Perform prototype receiving, pick-list processing, routing-sheet completion, stocking, inventory control, suspect-material quarantine, and production-part pull and lot-control activities as required.
Support VCT reject evaluation, rebuild, and applicable testing process flows; document results and escalate issues requiring engineering or quality review.
Serialize prototype components and assemblies; create and maintain build, inspection, traceability, and quality documentation; and prepare completed parts for shipment.
Use company databases, folders, Teamcenter, and other approved systems to retrieve project details, bills of material, drawings, and requirements, and enter or maintain inspection, quality, build, labor, and inventory information.
Use work instructions, procedures, job safety analyses, routing sheets, project records, and customer-order information to plan and document prototype work.
Contribute practical input to work instructions, routings, assembly methods, and manufacturability reviews based on prototype-build experience.
Inspect, pack, transport, and track prototype components and assemblies throughout the facility as required.
Manage prototype component inventory and participate in periodic inventory checks.
Coordinate with Inspection, Tool Room, Shipping, Production, and other departments to process and complete prototype components and assemblies.
Work with suppliers and internal stakeholders to clarify part condition, build readiness, documentation, and prototype processing needs.
Maintain clean, safe, and orderly work areas, tools, fixtures, and equipment, and perform required preventive-maintenance activities.
Follow applicable safety procedures, required training, PPE requirements, 5S, housekeeping, chemical-handling, SDS, emergency-response, material-handling, and workstation-control requirements.
Participate in department safety inspections, equipment checks, and corrective actions as assigned.