Plant Product Engineer Sr. II

BorgWarner; Thriftwood (SC); On-site; USD 101,000 - 142,000; Full time

Job summary

BorgWarner is seeking an experienced engineer to lead design, manufacturing, and cost-reduction initiatives for transfer case products. The role requires strong expertise in DFMA/DFM, DFMEAs, and APQP, with 8+ years in automotive product engineering and manufacturing.

The candidate will drive design-for-manufacturing, manage changes, and coordinate cross-functional teams to ensure robust designs and effective problem-solving across programs. Travel may be required.

Qualifications

• Bachelor's degree in engineering required; mechanical engineering preferred.
• 8+ years of automotive product engineering and manufacturing experience required.
• Experience with DFMEA, DFMA, and APQP encouraged.

Responsibilities

• Develop proposals for mechanical hardware and lead the estimation process for production changes.
• Lead design for manufacturing and assembly activities and develop design solutions to manufacturing issues, warranty issues, and cost reductions.
• Lead engineering change management process and DFMEA/DfM/DFx integration across programs.
• Lead design directions with issuing drawings, product specs, FEA analysis, and component designs.
• Develop technical documentation and engineering specifications for assemblies and sub-assemblies.

Skills

DFM

DFA

DFMEA

APQP

Root cause analysis

Problem solving

Cross-functional collaboration

Communication

GD&T

Manufacturing process knowledge

Driveline experience

Stamping processes

Metallurgy basics

Education

Bachelor's degree in engineering

Mechanical Engineering preferred

Job description

Key Accountabilities Work Estimate:

• 30% - Leads coordination and alignments for design for manufacturability and design for assembly (DFM/DFA) to ensure new and changing designs are robust for best practice product assembly.
• 30% - Leads engineering problem solving activities related to plant specific issues.
• 30% - Leads and organizes design cost reductions discussions and follow ups with all key stakeholder departments for the transfer case product.
• 10% - Lead brainstorming activities for future design changes, including initial engineering feasibility reviews.

Responsibilities:

• Develop proposals for mechanical hardware and lead the estimation process for production changes.
• Conduct meetings for design, build, open issues, problem-solving, and other subjects, as necessary.
• Lead design directions with issuing requests for drawings, product specification, FEA analysis, and component designs.
• Develop technical documentation and engineering specifications for the product assembly and sub-assemblies along with creating sub-system requirements definitions.
• Lead the prototype build process by working with purchasing to obtain parts, creating control plans, coordinating builds and tests, reviewing and approving incoming components, and signing off hardware for usage in internal and external testing.
• Lead team in the creation and maintenance of mechanical hardware assembly/system level DFMEAs.
• Lead team in problem solving for root cause investigation and solution creation.
• Escalating and reporting status of key mechanical issues to management.
• Lead the engineering change management process.
• Lead Design for Manufacturing and Assembly activities and develop design solutions to manufacturing issues, warranty issues, and cost reductions.
• Process and track designs in BorgWarner and customer engineering change management systems.
• Manage multiple design proposals and changes simultaneously.
• Lead system and component level stack up studies.
• Communicate effectively across functional groups.
• Exchange information with the relevant departments to optimize the product and the production process – DfA (Design for Assembly); DfM (Design for Manufacturing); DtC (Design to Cost)
• Analyze drawing deviations for functional risk and/or acceptance.
• Lead suppliers to improve quality, address non-conformance to drawings, and develop design cost reductions.
• Lead manufacturing and quality teams with problem solving product, design, and assembly issues.
• Conduct root cause analysis and implementation of effective solutions.

Knowledge/ Skills

• Self-motivation & self-starting work habits required.
• Proficiency in Microsoft Office applications - Word, Excel and PowerPoint required.
• Strong analytical ability and problem-solving experience required.
• Professional verbal and written communication skills required.
• Knowledge of GD&T is required.
• Experience and/or training in the development and maintenance of DFMEAs is required.
• Experience and/or training in DFM/DFA is required.
• Manufacturing and assembly process knowledge required.
• Experience with driveline systems and manufacturing process preferred.
• Experience with stamping, cleanliness, and fastening specifications preferred.
• General metallurgy knowledge preferred.
• General metallurgy knowledge is preferred, including steel, aluminum and magnesium.
• Experience and/or training in APQP is preferred.

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.
• This is an in-person role. The position requires employee to be present and available to perform assigned duties, attend required meetings and provide timely support to business operations.
• Wear PPE when appropriate in designated campus areas.
• Lifting shoulder high up to 35 lbs. on occasion.

Key Competencies

1. Decision Quality
2. Drives Results
3. Interpersonal Savvy
4. Manages Complexity
5. Manages Conflict
6. Functional/Technical Skills

Education & Experience

• Four-year bachelor’s degree in engineering required. Mechanical Engineering preferred.
• 8+ years experience in automotive product engineering and manufacturing is required.

EEO Statement “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.”

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

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.