The Senior Engineer - Assembly Manufacturing is responsible for developing and implementing new assembly processes and equipment for new product launches in line with BorgWarner standards, quality requirements, and project timelines. The role focuses on automation, productivity improvement, process optimization, and technology development by collaborating with global teams. The incumbent will also enhance existing assembly processes to achieve world-class standards in productivity, quality (Scrap/PPM), safety, and operational excellence through global benchmarking and continuous improvement initiatives.
* Design, develop, and implement new manufacturing processes and improvements for existing ones, focusing on efficiency, cost reduction, and quality enhancement.
* Lead and participate in problem-solving activities related to manufacturing issues, utilizing methodologies such as 8D, 5 Whys, and Ishikawa diagrams.
* Conduct process capability studies (CpK, PpK) and implement statistical process control (SPC) to monitor and maintain process stability.




* Develop and update manufacturing documentation, including work instructions, process flow diagrams, and control plans.
* Collaborate with design engineering, quality, and supply chain teams to ensure seamless Current Product Introduction (NPI) and smooth transitions into production.
* Identify and implement automation opportunities to improve productivity and reduce manual labor.
* Lead and mentor junior engineers and technicians, fostering a culture of continuous learning and improvement.
* Ensure compliance with all safety regulations, environmental standards, and company policies.
* Participate in lean manufacturing initiatives, including value stream mapping, Kaizen events, and 5S implementation.
* Analyze production data to identify trends, bottlenecks, and areas for improvement, proposing and implementing corrective actions.
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📌 Senior Engineer – Manufacturing (Kakkalur)
🏢 BorgWarner
📍 Kakkalur