Plant Product Engineer Sr. II

This position coordinates and performs design and development engineering, leads warranty resolution, and implements cost-reduction initiatives. Key activities include drawing revisions, tolerance stack-up analysis, and fastener and joint analysis.

Responsibilities include:

applying structured problem-solving methods to manufacturing and product-performance issues, communicating design and assembly concerns across functional teams, and leading product and process improvements.

• 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.

• 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 Borg Warner 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.

• 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.
• Experienc…