Sr. Process Engineer

Company Overview

Johnson Controls is a global leader in smart, healthy, and sustainable buildings. Our mission is to reimagine the performance of buildings to serve people, places, and the planet.

As a Sr. Process Engineer – New Product Introduction on the Stack Forging Thermal Solutions team, you will bring products from the lab into mass production. Your primary objective is to rapidly iterate and advance products to ensure they are manufacturable, cost‑effective, meet quality standards, and satisfy all requirements before launch.

• A hands‑on and creative problem‑solver eager to tackle complex technical challenges.
• A key contributor across multiple manufacturing steps such as laser cutting, metal–metal bonding, surface characterization, part geometry design, advanced data analysis, and material property optimization.
• Someone who can independently lead projects from concept through data collection and analysis to handoff to production, delivering parts that go directly to customers.
• Comfortable with high technical ownership, cross‑functional collaboration, and rapid troubleshooting in a fast‑paced environment.
• Willing to work 5 days onsite per week.

• Lead cross‑functional engineering projects by defining scope, managing timelines, and presenting results.
• Proactively identify, debug, and resolve complex process issues through experimentation and long‑term solutions.
• Collaborate with design, materials, and hardware teams to ensure constraints are integrated into the process.
• Perform thorough root‑cause analysis on parts and processes.
• Assemble and present detailed experimental results and technical findings to technical and non‑technical stakeholders.
• Design, implement, and maintain inline inspection and data collection systems to monitor process stability.
• Develop innovative support removal strategies and post‑processing techniques for novel part geometries and advanced materials.
• Ideate and champion long‑term technical improvements and strategic initiatives for the next generation of our manufacturing platform.

• Technical degree (BS/MS) with 7+ years of industry experience, or a Ph.D. with 3+ years of industry experience in Mechanical, System, Electrical, Controls, Advanced Manufacturing, or a related field.
• Proven ability to rapidly iterate and improve process methods to enhance throughput, yield, and reliability in manufacturing.
• Systems‑level thinking to understand trade‑offs across multiple process steps.
• Deep experience in at least one of: imaging processing, in‑line inspection/metrology, automation, hardware design, instrumentation and control systems, machine bring‑up/validation, or advanced statistical data analysis.
• Excellent written and verbal communication skills with the ability to present complex technical data.
• Statistically driven mindset for designing experiments, interpreting data, and making data‑backed decisions.
• Experience leading technical projects with cross‑functional teams that blend hardware, software, and manufacturing development.
• A "get it done" attitude, demonstrating resourcefulness and a drive to find creative solutions to difficult challenges.

• Proficiency with Python software coding for data analysis and automation.
• Readiness and enthusiasm to work in a dynamic environment with rapidly changing requirements and critical trade‑offs.
• Dynamic and flexible mindset, balancing day‑to‑day needs with long‑term strategic planning.

• Competitive salary
• Paid vacation, holidays, and sick time
• Comprehensive benefits package including 401(k), medical, dental, and vision care
• On‑the‑job and cross‑training opportunities
• Collaboration in a team environment
• Zero Harm safety policy

Salary Range: $97,000 – $162,000. Salary will be determined by the applicant’s education, experience, knowledge, skills, and abilities, internal equity, and alignment with market data. This role offers a competitive bonus plan based on individual, group, and corporate performance.