MQE / Controls Engineer

BorgWarner; Dixon (IL); On-site; USD 70,000 - 97,000; Full time

Benefits offered by this job

Day 1 Medical Coverage

Onsite Health Clinic

401k Matching

Paid Holidays

Job summary

BorgWarner in Dixon, IL is seeking a Controls Engineer to design, commission, and improve control systems for manufacturing and new product launches. You will lead automation projects and develop PLC, HMI, and SCADA solutions to enhance safety, quality, reliability, and productivity.

You will collaborate with manufacturing teams, coordinate equipment installations, travel to supplier sites as needed, and mentor technicians while applying best practices in safety and continuous improvement.

Qualifications

• Bachelor’s degree in a technical field related to controls automation.
• 3+ years of experience in Industrial Automation or Manufacturing Engineering.
• Ability to travel 5-10% for supplier and installation work.

Responsibilities

• Design, program, and improve PLC, HMI, and SCADA applications for manufacturing equipment.
• Develop electrical schematics, control-panel layouts, and wiring diagrams.
• Lead automation and digitalization initiatives including IIoT and predictive maintenance.
• Support equipment launch, installation, commissioning, and debugging activities.
• Collaborate with cross-functional teams to improve safety, quality, and productivity.

Skills

PLC programming

HMI/SCADA

Machine-vision

Industrial robots

Electrical schematics

Industrial protocols

SQL/Python/C++

Problem solving

Education

Bachelor's degree in Controls/Electrical/Mechatronics

Tools

Siemens STEP 7/WinCC

Allen-Bradley RSLogix/Studio 5000

Ignition

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

Salary Range:

$70,400 - $96,800

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