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

Dental, Vision, Life, AD&D, Disability

Tuition Reimbursement

401k with matching

Holidays and vacation from Day 1

Job summary

BorgWarner is hiring a Controls Engineer to design, develop, and optimize control systems and automated equipment for manufacturing operations and new product launches.

You will lead safety, quality, reliability, and productivity improvements, collaborate with cross-functional teams, and support equipment investments and installations. 3+ years in industrial automation is expected.

Qualifications

• Education: Bachelor’s degree in Controls Engineering, Electrical Engineering, Mechatronics Engineering, Automation Engineering, Robotics or related technical field from a four-year college or university.
• Experience: 3+ years in Industrial Automation, Controls, or Manufacturing Engineering (Internships or Co-Op included). Travel may be 5–10%.

Responsibilities

• Design, program, and improve PLC, HMI, and SCADA applications for manufacturing equipment.
• Develop and maintain electrical schematics, control-panel layouts, wiring diagrams, system configurations, operating procedures, troubleshooting guides, and training materials.
• Integrate sensors, actuators, motors, machine-vision systems, industrial networks, robotics, and related automation technologies.
• Lead automation and digitalization initiatives involving collaborative robots, autonomous mobile robots, IIoT, and predictive maintenance.
• Research and implement control-system, processing, and machine-safety best practices.

Skills

PLC programming

HMI/SCADA

Machine vision

Industrial robots

Electrical schematics

Ethernet/IP

Modbus

Profinet

IIoT

SQL

Python

C++

Troubleshooting

Documentation

Communication

Education

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

Tools

Siemens PLC

Allen-Bradley PLC

Ignition

Cognex

Keyence

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 and maintain electrical schematics, control-panel layouts, wiring diagrams, system configurations, operating procedures, 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 implement control-system, processing, and machine-safety best 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 and appropriation-request expenditures.

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, identify root causes, and validate corrective 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-product changes, and continuous-improvement projects.

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, and control-system documentation.
• 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, and timely closure 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, and continuous-improvement objectives.
• Perform other duties as assigned.

EDUCATION and/or EXPERIENCE

Education: Bachelor’s degree in Controls Engineering, Electrical Engineering, Mechatronics Engineering, Automation Engineering, Robotics or related technical field from a four-year college or university.

Experience: 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-panel design, and the ability to read and interpret electrical schematics.
• Knowledge of industrial communication protocols and networks, including Ethernet/IP, Modbus, and Profinet.
• Familiarity with industrial digitalization, IIoT concepts, 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-pace manufacturing environment.
• Effective communication, collaboration, project coordination, and technical-documentation skills.
• Ability to learn and apply new automation, controls, robotics, and manufacturing technologies.

Pay & Benefits

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

• 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 a global product leader in delivering innovative and sustainable mobility solutions. We are a company of innovators and independent thinkers that brings together talented employees, meaningful work and amazing technology in a unique environment. At BorgWarner we constantly work towards our vision of a clean and energy-efficient world. Our Culture BorgWarner promotes and nurtures a diverse and inclusive environment, honors integrity, strives for excellence, commits to responsibility for our communities and the environment, and builds on the power of collaboration. We believe the health and safety of our employees are a top priority.

Career Opportunities We manage talent as seriously as we manage our businesses and encourage you to learn about our proud history, strong culture, technologies, and vision for the future. We offer positions locally and globally with over 90 locations in 19 countries. If this position energizes you and you feel you can help us achieve our mission and vision, you are invited to submit an application for consideration. You may see the list of requirements and feel you do not meet all of them. However, remember that BorgWarner thinks differently. If your qualifications align with the majority of those outlined in this job description, we encourage you to apply and share your experience and skills with us.