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Senior Manufacturing Engineer

2 months ago

Seneca, South Carolina, United States BorgWarner Full time


To excel in this role, an individual must possess the capability to effectively carry out each essential responsibility.

The qualifications outlined below represent the knowledge, skills, and/or abilities required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Key Responsibilities:

Core Duties:


This position is primarily accountable for supporting production operations and enhancing processes for the assembly of intricate, precision components utilizing automated assembly technologies, including conveyor systems, robotics, and vision systems.

Additional duties encompass the acquisition of new machinery to facilitate capacity increases and new initiatives, as well as providing estimates for new business opportunities.


This role involves planning and executing tasks that require judgment in independent assessments, selection, and significant adaptation and modification of standard techniques, procedures, and criteria.

This necessitates the development of innovative solutions to challenges encountered.

For roles primarily focused on research, the completion of all requirements for a doctoral degree may be considered in lieu of experience.

Act as the process owner for a designated departmental function.

Assume full responsibility for a department that ensures a reliable, stable, and sustainable process concerning machinery, gauging, quality, tooling, capacity, and documentation.


Lead the new product introduction team responsible for formulating manufacturing strategies, including operator work content, machine capabilities, quality checks, and information flow.

Oversee the departmental planning team for capacity assessment and capital forecasting.

Identify parts, tools, and gauging necessary to meet manufacturing objectives according to product specifications.


Assess machine manufacturers through site evaluations, demonstrated capabilities, and financial considerations for the purpose of procuring new equipment to replace older machinery or to increase capacity.

Prepare and submit all purchase requisitions for new machining, assembly, and testing equipment. Responsible for quoting, developing, and qualifying the machinery with the manufacturer.


Once the equipment is on-site, lead the installation process (developing the installation plan and layouts), robotic integration, testing, and transition to full-time production.


Provide ongoing support for equipment after full-time production, including modifications for efficiency, capability, and continuous improvement; address any safety-related issues through troubleshooting and problem-solving.

Offer the necessary support to the department to maintain appropriate 5S standards.

Collaborate and assist production by participating in required daily meetings. Partner with operational leadership to jointly enhance departmental financial metrics.

Provide daily support to production and maintenance during machine downtimes through troubleshooting and problem-solving across various machine systems:

Mechanical, Electrical, Hydraulic, Pneumatic, Coolant, etc.

Respond to downtimes caused by tooling issues through troubleshooting and problem-solving. Work with tooling vendors to ensure the proper tooling is designed for the department.


Actively support any downtimes related to quality issues through troubleshooting and problem-solving using various problem-solving methodologies like 8D, Six Sigma, etc.

Manage the disposition of parts on hold concerning rework or scrapping.

Provide daily support for supplier materials in the event of quality issues.


Plan and design manufacturing processes aimed at achieving cost reductions while maximizing efficiency by analyzing equipment layout, workflow, assembly methods, and workforce utilization.

Will lead multiple cost-reduction initiatives.

Draft the necessary narratives to justify funding for cost-saving measures.


Utilize knowledge of GD&T, metrology, metallurgy, and assembly and testing processes to provide feedback to the product development team regarding manufacturability and create solutions to issues that arise during the review process.

Collaborate with design engineers to reduce costs on current projects and the development of future products.

Assist manufacturing associates by providing training to team leads and operators within the department.

Ensure proper spare parts are available by writing add-to-stock requests.

Update required documentation as necessary, including process sheets, control plans, FMEAs, FPPA, tool sheets, job instructions, etc. Responsible for all process documentation.

Support all shifts for manufacturing throughout the week and weekends, if necessary.

Perform tasks that involve conventional engineering practices. Manage a variety of complex features such as conflicting design requirements, unsuitability of standard materials, and challenging coordination requirements.

Knowledge/Skills:
Preferred knowledge in GD&T

Cleanliness processes

PLC programming (ladder logic)

Changeover optimization

Tooling optimization and testing

Project management

Troubleshooting

Problem-solving

Lean manufacturing

Additional Information:
Occasional travel may be required, up to 5% of the time.

Safety and Physical Requirements:
All employees are responsible for understanding and complying with safety policies and procedures.

Wear PPE when appropriate in designated areas.

Lifting up to 35 lbs. at shoulder height may be required on occasion.

Key Competencies:
Safety, Drive for Results, Functional Technical, Problem Solving, Process Management

Education & Experience:

Bachelor's Degree in Mechanical Engineering, Electrical Engineering, Electronic Engineering, Industrial Systems Engineering, or a related engineering discipline.

A Master's Degree in Engineering and experience in the automotive sector is preferred.

5+ years of experience in the automotive industry is preferred.

EEO Statement:

BorgWarner is an equal employment opportunity employer, ensuring that all qualified applicants receive consideration for employment without regard to race, color, age, religion, sex, sexual orientation, gender identity/expression, national origin, disability, or protected veteran status.

Internal Use Only:
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