Manufacturing Engineer Lead (Machining)

BorgWarner; Seneca (SC); Hybrid; USD 101,000 - 142,000; Full time

Job summary

BorgWarner seeks a Manufacturing Engineer/Leader to drive process ownership and continuous improvement on the machining floor. You will plan manufacturing plans for new products, ensure capacity and tool readiness, and lead design reviews with cross-functional teams.

The role requires extensive experience with CNC machining, GD&T, Lean practices, and project leadership. Occasional travel and multi-shift support may be involved as production needs demand.

Qualifications

• Knowledge of GD&T and metrology.
• Strong understanding of cleanliness processes.
• Experience with PLC programming (ladder logic).
• Ability to optimize changeovers and tooling.
• Experience optimizing and testing tooling.
• Proven project management skills.
• Able to troubleshoot diverse machinery and systems.
• Strong problem solving and Lean manufacturing knowledge.
• Experience with CNC machining and grinding.
• Awareness of Industry 4.0 concepts.

Responsibilities

• Own designated department process ensuring reliable, stable, and documented operations.
• Lead new product launch design of manufacturing plans including operator content and quality checks.
• Plan capacity and capital forecasts for department.
• Determine parts, tools, and gaging to meet specs.
• Evaluate and source equipment through site visits and financials.
• Oversee machine installation, robot integration, runoff and handoff to production.
• Support downtime and quality issues through root-cause analysis and 8D/6 Sigma approaches.

Skills

GD&T

Cleanliness

PLC programming

Changeover optimization

Tooling optimization

Project management

Trouble shooting

Problem solving

Lean manufacturing

CNC Machining/Grinding

Industry 4.0

Education

Bachelor’s Degree in Mechanical/Electrical/Electronic/Industrial Systems Engineering

Master’s Degree preferred

8 years engineering experience

2 years leading a technical team preferred

Job description

This position will be primarily responsible for production floor support and process improvement for the machining of complex, tight tolerance components utilizing CNC controlled lathes, mills, and grinding equipment.

This position plans and conducts work requiring judgment in independent evaluations, selection, and substantial adaptation and modification of standard techniques, procedures, and criteria. This requires devising new approaches to problems encountered. This role will lead a group of manufacturing engineers and hourly technicians.

Key Roles & Responsibilities

To perform this job successfully, an individual must have the ability to be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Standard Duties :

• Process owner of a designated departmental process. Fully responsibility for a department that provides a reliable, stable and sustainable process as it relates to machinery, gaging, quality, tooling, capacity, and documentation, etc.
• Leads the new product launch team which is responsible for designing manufacturing plans including operator work content, machine capability, quality checks and information flow.
• Leads the department planning team for capacity planning and capital forecasting.
• Determines parts, tools, and gaging needed to achieve manufacturing goals according to product specification.
• Evaluates machine builders through site visits, demonstrated capability and financial factors for the purpose of purchasing new equipment due to replacing current older equipment of for more capacity.
• Procures and writes all purchase requisitions for new machining, assembly and test equipment. Responsible for quoting, developing and qualifying the machine at the machine builder.
• Once the machine is onsite the persons leads the machine installation (developing the install plan and layouts), robotic integration, runoff and handoff to full time production.
• Ongoing support of equipment after full time production to include modifications for efficiency, capability and continuous improvement; Any issues that pertain to safety issues through troubleshooting and problem solving. Provides the proper support to the department to achieve the proper 5S levels
• Collaborates and supports the Area Production Leader (APL) for the department by attending the required daily meetings. Leads with the APL as they work together to improve the departmental financial metrics.
• Daily supports production and maintenance due to machine downtime through trouble shooting and problem-solving different machine systems:
• Mechanical
• Electrical
• Hydraulic
• Pneumatic
• Coolant
• Respond to downtime due to tooling issues through troubleshooting and problem solving. Works with each of the tooling vendors to provide the proper designed tooling in the department.
• Actively support any downtime as it pertains to quality issues through troubleshooting and problem solving using different problem-solving applications like 8D, 6 Sigma, etc.
• Dispositions of the parts on hold as it pertains to rework or to be scrapped.
• Daily supports the incoming material suppliers if quality issues happen.
• Plans and designs manufacturing processes to produce cost reductions which maximizes efficiency by analyzing layout of equipment, workflow, assembly methods, and work force utilization. Will lead multiple cost reduction projects.
• Writes the required AR narratives to justify the funding needed for cost reductions.
• Utilizes knowledge of GD&T, metrology, metallurgy and assembly and test processes to provide feedback to the product development team on manufacturability and create solutions to issues that arise throughout the review process. Works with the design engineers to reduce cost on current projects and the developmental of future products.
• Assists manufacturing associates by provided the training to the team leads and operators within the department.
• Writes add to stocks to make sure we have the correct spare parts on hand.
• Develops/updates the required documents like process sheets, control plans, FMEA’s, FPPA, tool sheets, job instructions, etc. Responsible for all process documentation.
• Supports all shifts for manufacturing during the week and weekends, if necessary.
• Performs work that involves conventional engineering practice. Controls a variety of complex features such as conflicting design requirements, unsuitability of standard materials, and difficult coordination requirements

Knowledge/Skills

• Knowledge in the following areas is preferred:
  • GD&T
  • Cleanliness processes
  • PLC programming (ladder logic)
  • Changeover optimization
  • Tooling optimization and testing
  • Project management
  • Trouble shooting
  • Problem solving
  • Lean manufacturing
  • CNC Machining/Grinding
  • Industry 4.0

Additional Information:

• Travel is occasionally required, up to 5% of the time.

Safety and Physical Requirements:

• All employees are responsible for knowing, understanding and complying with the safety policies and procedures.
• Wear PPE when appropriate in designated campus areas.
• Lifting shoulder high up to 35 lbs. on occasion.

Key Competencies

• Safety
• Drive for Results
• Functional Technical
• Problem Solving
• Process Management

Education & Experience

• Bachelor’s Degree in Mechanical Engineering or Electrical Engineering or Electronic Engineering or Industrial Systems Engineering or related engineering degree discipline required.
• Master’s Degree preferred
• 8 years’ engineering experience is required
• 2 years’ of leading a technical team is preferred

EEO Statement

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

Salary Range: $100,800 - $141,750

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