Senior Prototype Assembly Technician

BorgWarner; Auburn Hills (MI); On-site; USD 52,000 - 78,000; Full time

Job summary

BorgWarner is seeking a Senior Prototype Assembly Technician for our Prototype Operations team in Ithaca, NY. This role supports assembly, inspection, processing, documentation, and troubleshooting of prototype components to engineering specifications.

The position requires hands-on experience with prototype builds, measurement tools, and a strong focus on quality, traceability, and collaboration with cross-functional teams to meet project goals.

Qualifications

• HS diploma or equivalent required.
• 5+ years in prototype assembly/inspection/processing.
• Ability to read engineering drawings, BOMs, and process docs.
• Proficient with hand tools, power tools, presses, riveters, and prototype shop equipment.

Responsibilities

• Select, inspect, and assemble prototype parts per drawings, BOMs, and specs.
• Assemble components and subassemblies per work instructions and prints.
• Operate and set up basic assembly and measurement equipment.
• Document results, traceability, and inventory for prototypes.
• Coordinate with engineering, quality, and manufacturing to resolve prototyping issues.

Skills

Change Management

Future State

Engineering Standards

Gap Analysis

Project Scheduling

Education

High school diploma or equivalent

Associate degree or technical training preferred

Job description

Supports prototype operations through component inspection, assembly, processing, documentation, and troubleshooting. Selects and prepares parts; builds prototype components, subassemblies, and assemblies to engineering specifications; performs in-process dimensional checks; and maintains traceability, inventory, and build records to support prototype programs and engineering evaluations.

BorgWarner is the recognized leader in advanced products and technologies that satisfy customer needs in powertrain components and system solutions.

JOB DESCRIPTION

Job Title:

Senior Prototype Assembly Technician

Functional Department:

Prototype Operations

Primary Job Location:

Ithaca, NY

Global Grade:

Grade 9

Employment Status:

Full Time

FLSA Status:

To be determined

Date:

October 15, 2026

POSITION SUMMARY

Supports prototype operations through component inspection, assembly, processing, documentation, and troubleshooting. Selects and prepares parts; builds prototype components, subassemblies, and assemblies to engineering specifications; performs in-process dimensional checks; and maintains traceability, inventory, and build records to support prototype programs and engineering evaluations.

KEY ROLES AND RESPONSIBILITIES

• Selects, identifies, and inspects prototype parts against engineering drawings, bills of material (BOMs), specifications, and project requirements before assembly.
• Assembles prototype components, subassemblies, and assemblies using engineering prints, work instructions, process flow information, and direction from Prototype supervision or engineering.
• Performs fit-up, alignment, fastening, pressing, riveting, staking, pre-stressing, scribing, and other manual assembly operations required for prototype builds.
• Opens drill presses, arbor presses, bench grinders, parts washers, riveters, pre-stress machines, and other approved shop equipment and hand tools to build or modify prototype parts and fixtures.
• Sets up and operates torque drivers and torque meters, seating and rivet stations, prestress equipment, marking and serialization equipment, scales, gage pins, height gages, drop gages, indicators, and approved assembly fixtures used for prototype work.
• Verifies fixture condition and readiness before use and maintains organized storage of assembly fixtures, tooling, and measurement equipment.
• Makes minor component modifications from drawings or other approved graphic information using common and specialized hand and power tools.
• Uses micrometers, calipers, dial indicators, center-distance measurement equipment, and other basic or semi-complex inspection tools to verify component and assembly requirements.
• Identifies assembly or dimensional concerns, documents findings, and works with Product, Manufacturing, and Quality Engineering to resolve issues affecting prototype builds.
• Hand assembles, pre-stresses, measures, and scribes HyVo, roller, bush, and inverted-tooth (Silent) chains.
• Hand assembles timing-drive products including tensioners, arms, guides, hydraulic Variable Cam Timing phasers (hVCTs), and electric Variable Cam Timing phasers (eVCTs).
• Processes and supports prototype arms, guides, sprockets, mechanical and hydraulic tensioners, center bolts, solenoids, check valves, pressure-relief valves, timing chains, and Variable Cam Timing (VCT) phaser units in accordance with applicable work instructions and project requirements.
• Performs prototype receiving, pick-list processing, routing-sheet completion, stocking, inventory control, quarantine of suspect material, and production-part pull and lot-control activities as required.
• Supports VCT reject evaluation, rebuild, and applicable testing process flows; documents results and escalates conditions requiring engineering or quality review.
• Serializes prototype components and assemblies; creates and maintains build, inspection, traceability, and quality documentation; and prepares completed parts for shipment.
• Accesses company databases and folders to obtain project details, BOMs, drawings, and requirements; enters inspection, quality, build, and inventory information using company computer systems.
• Uses applicable work instructions, procedures, job safety analyses, routing sheets, project records, and customer-order information to plan and document prototype processing and assembly activities.
• Navigates Teamcenter and other approved company systems to retrieve drawings and requirements; completes electronic filing, record retention, labor tracking, inspection entries, and inventory transactions applicable to the role.
• Contributes practical input to new or revised work instructions, routings, assembly methods, and manufacturability reviews based on prototype‑build experience.
• Inspects, packs, transports, and tracks prototype components and assemblies throughout the facility as required.
• Manages prototype component inventory and participates in periodic inventory checks.
• Coordinates with Inspection, Tool Room, Shipping, Production, and other departments for processing and completion of prototype components and assemblies.
• Works with suppliers and internal stakeholders to clarify part condition, build readiness, documentation, and prototype processing needs.
• Maintains work areas, tools, fixtures, and equipment in a clean, safe, and orderly condition and performs required preventive‑maintenance activities.
• Performs work in accordance with applicable safety procedures, required training, and personal protective equipment requirements.
• Follows 5S, housekeeping, chemical handling, Safety Data Sheet (SDS), emergency-response, material‑handling, and workstation‑control requirements applicable to prototype operations.
• Participates in department safety inspections, equipment checks, and corrective actions as assigned.

JOB REQUIREMENTS AND QUALIFICATIONS

EDUCATION AND EXPERIENCE

• High school diploma or equivalent is required.
• Associate degree or two (2) years of technical training is preferred.
• Minimum five (5) years of practical experience supporting prototype component and assembly operations, including assembly, inspection, fabrication, processing, or troubleshooting.
• Demonstrated mechanical ability and aptitude, including safe use of hand tools, power tools, presses, riveters, and general prototype‑shop equipment.
• Ability to read and understand engineering drawings, specifications, bills of material, and process‑flow documentation.
• Ability to use conventional dimensional inspection equipment and apply decimals, fractions, and basic arithmetic.
• Ability to follow work instructions, procedures, routing sheets, job safety analyses, and established prototype processing requirements.
• Ability to learn and safely operate role‑specific assembly, marking, material‑handling, inspection, and packaging equipment through formal and on‑the‑job training.
• Working knowledge of prototype receiving, stock control, pick‑list processing, packing, labeling, shipping preparation, quarantine, traceability, and record‑retention practices is preferred.
• Ability to enter, retrieve, and review project, inspection, quality, and inventory data using company computer systems and Microsoft Office applications.
• Must have strong problem-solving and troubleshooting skills and the ability to make sound decisions with limited information.
• Must have professional interpersonal communication skills and be able to coordinate effectively with engineering, quality, manufacturing, production, tool‑room, inspection, shipping, and supplier contacts.

CORE COMPETENCIES

• Customer Focus
• Functional/Technical Skills
• Problem Solving
• Quality and Attention to Detail
• Priority Setting
• Collaboration and Communication
• Learning Agility
• Drive for Results
• Safety and Accountability

PHYSICAL DEMANDS

The physical demands described here are representative of those required to perform the essential functions of this job. Reasonable accommodations may be made to enable qualified individuals to perform the essential functions. The position requires standing and walking, frequent use of hands and fingers, close visual attention, handling of prototype components and tooling, and occasional bending, kneeling, reaching, or lifting as required by assigned work. Specific frequency and lifting limits should be confirmed through the applicable HR and EHS review process.

EEO STATEMENT

It is the policy of BorgWarner to provide equal employment opportunity to all applicants and employees in accordance with applicable federal, state, and local law.

Skills:

Change Management, Define Future State, Engineering Standards and Compliance, Perform Gap Analysis, Project Schedule Management

Salary Range:

Internal Use Only: Salary