Sr. Automation and Controls Engineer

BorgWarner; Royal Pines (NC); On-site; USD 80,000 - 110,000; Full time

Job summary

An established industry player is seeking a skilled Senior Controls Engineer to innovate manufacturing processes and enhance automation capabilities. This role involves collaborating with teams to design equipment, implement advanced controls, and ensure product quality and safety. The ideal candidate will leverage their expertise in PLC programming, robotics, and machine vision to drive continuous improvement initiatives. Join a company committed to creating a cleaner, energy-efficient world, where your contributions will play a vital role in shaping the future of mobility solutions. Embrace this opportunity to work in a dynamic environment that values innovation and collaboration.

Benefits

Day 1 Medical Coverage

Onsite Health Clinic

Dental Coverage

Tuition Reimbursement

401k Matching Program

Paid Holidays

Paid Vacation

Qualifications

• 6+ years in manufacturing or engineering, with expertise in PLC programming.
• Experience with machine vision systems and robotic programming is crucial.

Responsibilities

• Collaborate to design and enhance manufacturing equipment and controls.
• Lead automation initiatives and integrate AI for predictive maintenance.

Skills

Problem-solving skills

Communication skills

Programming Allen Bradley PLCs

Machine vision systems integration

Robotic systems programming

SQL database management

Project management

Education

Bachelor’s degree in Controls Engineering

Equivalent industry experience

Tools

Allen Bradley PLCs

Siemens SIMATIC PLCs

Cognex 2D/3D

Fanuc robots

SAP

Microsoft Office Suite

Ignition modules

Job description

Sr. Automation and Controls Engineer II

Arden, NC

BorgWarner is a global product leader in delivering innovative and sustainable mobility solutions for the vehicle market. 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

We believe the health and safety of our employees are a top priority. We care about our local communities and the global environment. 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.

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 future vision. We offer a strong local presence and interesting global opportunities. Start your future with BorgWarner now!

All positions start at an above market pay rate for that position. Benefits are also above market and include the 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

The BorgWarner Arden campus offers two world class technical centers and a cutting-edge manufacturing facility that designs and produces turbos, fan, and fan drive components for the automotive industry. The Arden campus offers a multitude of career opportunities and is in the beautiful mountains of Western North Carolina.

We are seeking a highly skilled Senior Controls Engineer to enhance our manufacturing capabilities by developing and implementing innovative controls engineering solutions. This role will focus on maintaining the highest standards of safety, product quality, and cost-efficiency while leading continuous improvement initiatives and special projects. The ideal candidate will work collaboratively with various teams across the organization and interface effectively with equipment vendors and external partners.

Key Responsibilities:

• Collaborate with Manufacturing Engineers to design and enhance equipment and controls for new and existing products, focusing on cycle time reduction, quality improvement, and waste minimization.
• Lead initiatives to implement process automation using robots and collaborative robots, enhance shopfloor digitalization, and drive IoT initiatives for advanced process analysis and predictive maintenance.
• Champion the integration of machine learning and artificial intelligence to predict early machine failures and detect potential quality issues.
• Utilize Digital Twins for process modeling and real-time data for process optimization, including the development of dashboards and process analytics for comprehensive insights.
• Partner with Maintenance teams to troubleshoot equipment issues, minimize downtime, and oversee equipment relocation or modifications.
• Manage and maintain control programs (PLC, vision systems, robotics, databases, SCADA) utilized in the production process.
• Support the specification and installation of new equipment, ensuring comprehensive safety reviews and the integration of control systems with data collection platforms (e.g., SCADA, MES, ERP).
• Engage with equipment suppliers and contractors to oversee the installation and upgrading of production equipment.
• Lead and contribute to cross-functional teams across local and global operations to drive organizational goals.
• Ensure all design and implementation efforts adhere to ISO standards, RIA standards, OSHA regulations, and internal quality systems.
• Travel as needed to vendor locations for equipment inspections, tests, and installations.
• Maintain compliance with standard manufacturing practices and current control policies.
• Identify and resolve safety issues through proactive measures and corrective action implementation.
• Carry out other duties as directed or assigned.

Education Requirements:

• Bachelor’s degree in Controls Engineering, Electrical Engineering, Mechatronics Engineering, Automation Engineering, Robotics, or Computer Science. Equivalent industry experience may be considered.

Experience Requirements:

• 6+ years of relevant experience in a manufacturing or engineering environment.
• Proven expertise in programming and troubleshooting Allen Bradley PLCs and HMIs (RSLogix 5000, RSLogix 500).
• Experience with Siemens SIMATIC PLCs.
• Demonstrated ability to program and integrate machine vision systems (required: Cognex 2D/3D; Keyence experience is a plus).
• Strong background in designing, programming, and deploying robotic and collaborative robotic systems.
• Proficiency in programming and troubleshooting Fanuc robots/cobots (EPSON and additional robotic platforms are advantageous).
• Competence in SQL database management, including interfacing with PLCs via RSSQL, FTTM (Factory Talk Transaction Manager), or Ignition.
• Knowledge of SQL programming and Stored Procedures.
• Experience designing and managing safety systems within an industrial setting.
• Familiarity with automotive product manufacturing (e.g., engine systems) is preferred.
• Basic knowledge of SAP and experience interfacing manufacturing systems with APIs; advanced SAP knowledge is a plus.
• Proficiency in Microsoft Office Suite (Word, Excel, PowerPoint, Outlook).
• Expertise with Ignition modules (Ignition Perspective, Transaction Groups, Vision, Database Connections, IoT integration, shopfloor device connections).
• Experience in process data collection via integrated systems.
• Capability to design and implement API connections using Python, Java, or MS.NET. (JSON, MQTT, RESTful, Web Services, etc.)
• A minimum of 3 years of experience working with automated machinery in a manufacturing context is preferred.
• At least 1 year of project management experience, including cost justification, planning, and milestone management, is desirable.

Key Competencies:

• Excellent problem-solving skills and proactive approach to troubleshooting.
• Strong verbal and written communication skills for effective team collaboration and documentation.
• Commitment to core values:
  • Inclusion: Respecting individuals
  • Integrity: Honoring truth
  • Excellence: Focusing on results
  • Responsibility: Commitment to duties
  • Collaboration: Building trust

This position will adhere to the BorgWarner Environmental Health and Safety Program by following all safety rules, procedures, practices, training, and safe use of equipment; this includes use of personal protective equipment (PPE) as required. This individual will work in a way that stresses the importance of preventing injury, accidents, or illnesses to themselves or co-workers by correcting or reporting unsafe situations, incidents, or occurrences to their Team Lead immediately.

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.

Join the company that is creating solutions that support a cleaner, more energy-efficient world.

For more information about BorgWarner, please visit www.borgwarner.com