MQE / Controls Engineer

Borgwarner Emissions Systems Spain SL; Dixon (IL); On-site; USD 70,000 - 97,000; Full time

Benefits offered by this job

Day 1 medical coverage

Onsite health clinic

Dental and vision coverage

Tuition reimbursement

401(k) with company match

Paid holidays and vacation

Job summary

BorgWarner Emissions Systems Spain SL in Dixon, IL seeks a Controls Engineer who will design, develop, program, and improve PLC, HMI, and SCADA applications for manufacturing equipment and processes, while enhancing safety, quality, reliability, and productivity.

You will lead continuous-improvement initiatives, support equipment investments and installation, coordinate with suppliers and cross-functional teams, travel to supplier sites for inspections and commissioning, and document procedures

Qualifications

• Bachelor's degree in a relevant technical field.
• 3+ years in Industrial Automation, Controls, or Manufacturing Engineering.

Responsibilities

• Design, develop, program, and improve PLC, HMI, and SCADA applications for manufacturing equipment and processes.
• Develop and maintain electrical schematics, control-panel layouts, wiring diagrams, and system configurations.
• Lead automation and digitalization initiatives including collaborative robots and IIoT technologies.
• Support equipment design reviews, installation, commissioning, and production launches.
• Coordinate technicians, suppliers, and cross-functional partners during new equipment installations and upgrades.
• Travel to supplier locations for inspections, testing, installations, and launch support.
• Diagnose and repair control and equipment issues and coordinate maintenance and calibration.

Skills

PLC programming

HMI/SCADA experience

Machine-vision systems

Industrial robots

Electrical schematics

Industrial protocols

IIoT concepts

SQL

Python

Ladder logic

Analytical problem-solving

Technical communication

Education

Bachelor’s degree in Controls/Electrical/Mechatronics/Automation/Robotics or related field

Tools

Siemens PLC

Allen-Bradley PLC

Ignition (SCADA)

Cognex/Keyence vision

Fanuc/ABB/KUKA robots

Job description

Provide electrical, controls, automation, and machine-safety engineering support for manufacturing operations and new product launches. This role designs, develops, commissions, and improves control systems and automated equipment to enhance safety, quality, reliability, productivity, and customer satisfaction. The Controls Engineer also leads continuous-improvement initiatives, supports equipment investment and installation, and serves as a technical resource to manufacturing teams and technicians.

RESPONSIBILITIES AND ACCOUNTABILITIES:

Controls and Automation Engineering

• Design, develop, program, and improve PLC, HMI, and SCADA applications for manufacturing equipment and processes.

• Develop andmaintainelectrical schematics,control-panellayouts, wiring diagrams, system configurations,operatingprocedures, troubleshooting guides, and training materials.

• Integrate and support sensors, actuators, motors, machine-vision systems, industrial networks, robotics, and related automation technologies.

• Lead automation and digitalization initiatives involving collaborative robots, autonomous mobile robots, Industrial Internet of Things technologies, advanced process analysis, and predictive maintenance.

• Research and implementcontrol-system, processing, andmachine-safetybest practices consistent with plant standards and control policies.

Equipment Launch, Commissioning, and Support

• Support equipment design reviews,selection, quotation, installation, commissioning, debugging, testing, and production launch activities.

• Coordinate manufacturing technicians, suppliers, contractors, and cross-functional partners during new-equipment installations, upgrades, and product launches.

• Travel to supplier locations as needed for equipment inspections, acceptance testing, installations, and launch support.

• Diagnose control and equipment issues and coordinate maintenance, repairs, calibration, modifications, and restoration of production capability.

• Evaluate and justify new equipment and process investments, coordinate implementation, and support tracking of tooling andappropriation-requestexpenditures.

Manufacturing Quality and Continuous Improvement

• Analyze engineering specifications and manufacturing processes to create/develop test plans, automated test tools, and verification of equipment.
• Support end-of-line (EOL) test systems and validate product performance against customer requirements.

• Investigate product and process quality issues,identifyroot causes, andvalidatecorrective actions through documented testing and analysis.

• Plan and perform process studies, design of experiments, capability evaluations, and other technical analyses.

• Partner with manufacturing and product engineering teams to improve equipment safety, quality, capability,utilization, reliability, and cost performance.

• Support new product introductions,current-productchanges, andcontinuous-improvementprojects.

Technical Leadership, Documentation, and Safety

• Provide technical direction, training, and support to technicians, manufacturing teams, peers, and new team members.

• Prepare and deliver technical presentations to customers, employees, and management, and coordinate outside contract projects.

• Establish and maintain effective equipment, process, andcontrol-systemdocumentation.

• Develop work procedures that reduce operational risk, train employees on those procedures, and support consistent application.

• Support workplace inspections, incident investigations, root-cause corrective actions, safety meetings, training, andtimelyclosure of identified safety issues.

• Comply with applicable safety standards, industry regulations, company policies, and standard manufacturing practices.

• Participate in cross-functional teams, including Production Teams and AQP Steering Committee activities, to achieve safety, quality, launch, andcontinuous-improvementobjectives.

• Perform other duties as assigned.

EDUCATION and/or EXPERIENCE:

• Bachelor’s degree in Controls Engineering, Electrical Engineering, Mechatronics Engineering, Automation Engineering, Robotics or related technical field from a four-year college or university.
• 3+ years of experience in Industrial Automation, Controls, or Manufacturing Engineering (Internships or Co-Op experience included).
• Ability to travel with minimal notification may arise for 5-10%.

KEY JOB SKILLS/EXPERIENCE:

• PLC programming and troubleshooting experience with Siemens and/or Allen-Bradley platforms.

• Experience developing or supporting HMI and SCADA applications; Ignition experience preferred.

• Experience with machine-vision systems such as Cognex or Keyence.

• Working knowledge of industrial robots, including Fanuc, ABB, KUKA, or similar platforms.

• Knowledge of electrical circuits,control-paneldesign, and the ability to read and interpret electrical schematics.

• Knowledge of industrial communication protocols and networks, including Ethernet/IP, Modbus, andProfinet.

• Familiarity with industrial digitalization,IIoTconcepts, and data-driven process monitoring.

• Programming or data-query experience using SQL, Python, C++, ladder logic, or comparable languages.

• Strong analytical, troubleshooting, and problem-solving skills in a fast-paced manufacturing environment.

• Effective communication, collaboration, project coordination, andtechnical-documentationskills.

• Ability to learn and apply new automation, controls, robotics, and manufacturing technologies.

For a listing of Dixon openings: BorgWarner Openings

Pay & Benefits

Annual Salary Range: $ 70,400 - $ 96,800

Benefit info: U.S. Benefits - BorgWarner

Some of the benefits highlights below for all fulltime employees:

• Day 1 Medical Coverage with potential of no monthly premium
• Onsite Health Clinic for employees and dependents (age 14 and over) at no cost
• Dental, Vision, Life, AD&D, and Disability Coverage
• Tuition Reimbursement Program after 18 months
• Retirement Savings Plan (401k) with a matching program
• Company paid holidays and vacation starting Day 1

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.