Sr. Manufacturing Engineer-Thermal Assembly

BorgWarner•Arden, NC

1d•$80,800 - $111,100•Onsite

About The Position

The Sr. Manufacturing Engineer – Thermal Assembly provides technical leadership and support for manufacturing processes and practices in an automotive or commercial vehicle component production environment at BorgWarner’s Arden campus, which designs and produces turbochargers, fans, and fan drive components. The role supports manufacturing operations in process development, improvement, testing, safety, quality, and cost, with particular focus on thermal assembly and related production systems. The engineer works with product line managers, vendors, customers, product development engineering, maintenance, and cross-functional teams to develop and improve automated and manual systems, source and commission equipment and custom tools, and address manufacturing and quality issues. The role also evaluates production costs and workflows, supports manufacturability and process improvements, and applies project management and quality methods to improve operational performance while following health, safety, and environmental requirements.

Requirements

At least 5 years of Manufacturing Engineering experience in semi-automated or automated assembly lines.
Understanding of the APQP process.
Understanding of lean manufacturing principles.
Experience with quality and lean processes and tools, including PPAP, statistical analysis, 8D, and 5S.
Proficiency with Microsoft Office software, including Word, Excel, PowerPoint, Outlook, Teams, and SharePoint.
Ability to work in a team environment and follow instructions, safety rules, and regulations.
Strong desire to learn, grow, and solve problems to improve the production system and the experience of those who work in it.
Attendance on the job is essential.

Nice To Haves

Bachelor of Science in mechanical or electromechanical engineering; described as ideal.
Affinity for mechanical and electromechanical engineering and problem solving.
Automotive industry experience.
Cognex Vision system programming experience.
DC electric torque systems experience.
Working knowledge of Allen Bradley PLC programming.
Experience with servo press equipment.
Experience with robotic assembly equipment.
Experience with Allen Bradley control systems.
Knowledge of SAP.
DFMEA, 3P, Design for Value, or Design for Six Sigma skills.
CAD platform experience, such as Solid Works, AutoCAD, Creo, Pro-E, or Inventor.
Knowledge of fan drive products.

Responsibilities

Support manufacturing operations in process development, improvement, testing, safety, quality, and cost.
Coordinate with Product Line Managers, vendors, customers, and Product Development engineering to ensure customer satisfaction and adherence to BorgWarner World Class manufacturing standards.
Develop and enhance automated and manual systems for machine tending, material handling, and assembly operations.
Develop and enhance manufacturing operations involving thermal assembly, balancing, fluid transfer systems, servo pressing, and in-process and post-process gauging and verification systems.
Generate RFQ specifications for new equipment and custom tools.
Obtain cost estimates and proposals for planned growth and evaluate suppliers for quality, capability, and reliability.
Lead sourcing of new equipment and custom tools from RFQ through commissioning and start of production; coordinate project needs, timing, capital forecasting, spare parts procurement, and stocking with cross-functional teams.
Review and calculate labor, material, and other production costs, and review schedules and future production requirements to support management decision-making.
Analyze and plan workflow, equipment placement, and space requirements to improve manufacturing efficiency while adhering to health, safety, and environmental policies.
Coordinate equipment maintenance, preventative maintenance needs, and repair services with Maintenance team members.
Provide technical guidance to the team on manufacturability, cost, testing, and process improvements.
Use project management tools such as flow charting, mapping, PFMEA, and timelines to develop solutions in collaboration with other Manufacturing Engineers.
Stay current on industry trends in equipment, tooling, gauging, testing, and integration systems, and apply relevant knowledge to advise the organization.
Drive 8D or similar quality problem-solving processes, identify root causes, implement corrective actions, and verify their effectiveness.
Maintain confidentiality of privileged information.
Facilitate the change process at the technical level and act in line with company core values and beliefs.
Perform other duties as requested or assigned.
Follow BorgWarner Environmental Health and Safety rules, procedures, practices, training, and equipment requirements, including required PPE; prevent, correct, or promptly report unsafe situations, incidents, and occurrences.