Senior Prototype Assembly Technician

BorgWarner•Ithaca, MI

About The Position

The Senior Prototype Assembly Technician supports prototype operations through component inspection, assembly, processing, documentation, and troubleshooting. The role selects and prepares parts; builds prototype components, subassemblies, and assemblies to engineering specifications; performs in-process dimensional checks; and maintains traceability, inventory, 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. The role performs manual assembly and component modification, operates approved shop and measurement equipment, identifies and documents assembly or dimensional concerns, and collaborates with engineering, quality, manufacturing, production, inspection, tool-room, shipping, and supplier contacts. It also supports prototype receiving, inventory control, serialization, documentation, packaging, and shipment preparation. The position is based in Ithaca, New York, and is full-time. It requires a high school diploma or equivalent and at least five years of practical experience supporting prototype component and assembly operations. An associate degree or two years of technical training is preferred.

Requirements

High school diploma or equivalent.
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 and 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, hand tools, assembly equipment, fixtures, and measurement equipment to build or modify prototype parts and fixtures.
Verify fixture condition and readiness before use, and maintain organized storage of fixtures, tooling, and measurement equipment.
Make minor component modifications using drawings or other approved graphic information and common or specialized hand and power tools.
Use dimensional inspection tools to verify component and assembly requirements.
Identify assembly or dimensional concerns, document findings, and work with Product, Manufacturing, and Quality Engineering to resolve prototype-build issues.
Hand assemble, pre-stress, measure, and scribe HyVo, roller, bush, and inverted-tooth (Silent) chains.
Hand assemble timing-drive products, including tensioners, arms, guides, hVCT phasers, and eVCT phasers.
Process and support prototype arms, guides, sprockets, tensioners, center bolts, solenoids, check valves, pressure-relief valves, timing chains, and VCT phaser units in accordance with work 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 processes; document results and escalate conditions 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.
Access company databases and folders for project details, bills of material, drawings, and requirements, and enter inspection, quality, build, and inventory information in company systems.
Use work instructions, procedures, job safety analyses, routing sheets, project records, and customer-order information to plan and document prototype processing and assembly.
Retrieve drawings and requirements in Teamcenter and other approved systems; complete electronic filing, record retention, labor tracking, inspection entries, and inventory transactions applicable to the role.
Contribute practical input to new or revised work instructions, routings, assembly methods, and manufacturability reviews.
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 on processing and completion of 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.
Follow safety procedures, training, personal protective equipment 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.