Reliability Test Engineer; onsite

About Us

We are a diverse, enthusiastic, and growing team of multidisciplined engineers committed to advancing our mission of delivering mission-critical environments where it really matters through functionality, performance, and reliability of HVACR products meet and exceed demanding uptime and performance targets for applications such as data centers, commercial buildings, and industrial facilities. We work across multiple development programs and often step outside our normal roles to support a fast-paced environment.

Johnson Controls is a diverse, enthusiastic, and growing company of multidisciplined employees committed to advancing our mission of delivering mission-critical environments where it really matters through functionality, performance, and reliability of HVACR products meet and exceed demanding uptime and performance targets for applications such as data centers, commercial buildings, and industrial facilities. We work across multiple development programs and often step outside our normal roles to support a fast-paced environment.

Johnson Controls is seeking a hands-on Reliability Test Engineer, who will partner directly with design, controls, testing, manufacturing, service, and supplier teams to deliver reliability by design for our chiller portfolio. You will have the opportunity to learn more about compressors (screw, centrifugal, scroll), heat exchangers, pumps, fans, VFDs (Variable Frequency Drives), power electronics, sensors/actuators, and control systems and the interactions among them to ensure products meet stringent reliability, availability, and maintainability goals over the entire lifecycle.

You will apply DFMEA (Design Failure Modes & Effects Analysis), Accelerated testing, RCA (Root Cause Analysis)/8D (Problem solving), and statistical life data analysis to drive decisions. This position is based in New Freedom, PA. Candidates must be commuting distance, or able to relocate.

• Own and drive the reliability strategy across air-cooled and water-cooled chiller programs with clear goals for failure-rate reduction, B10 life, and warranty cost.
• Translate design intent into reliability plans (Design-for-Reliability, DVP&R - Design Verification Plan, and Results) ensuring coverage of likely failure modes under realistic environmental and load profiles (thermal cycling, vibration, electrical stress, fouling).
• Manage and report reliability status for all programs - dashboards, risk registers, and readiness for phase gates - leading data-driven decisions.
• Connect field failure modes with validation standards and plans; update strategies as new field learnings emerge.
• Requirements and validation methods to ensure what's written matches how it's verified and validated.
• Program test strategies to maximize coverage and reduce redundant testing.
• Program readiness at key milestones (concept, design freeze, design validation, product validation, launch).
• Conduct Root Cause Analysis (RCA/8D) on chronic issues across disciplines (e.g., bearing wear, VFD trips, refrigerant leaks, corrosion) and implement systemic corrective actions.
• Standardize reliability practices (DFMEA, Accelerated testing) with principal engineers and align supplier qualifications to reliability needs.

Required

• Bachelor's degree in Mechanical, Mechatronics, Electrical, or related engineering discipline.
• 0-3 years of experience in product development, test, or field reliability;
• Understanding of FMEA, RCA, recreating failure modes, and statistical analysis (e.g., Weibull).
• Demonstrated aptitude for debugging and troubleshooting in lab and field environments; strong curiosity and systematic problem solving.

• Certified Reliability Engineer (ASQ-CRE) or equivalent, and understands distributions, Life-Stress models, Reliability allocations, Design of Experiments (DoE).
• Ability to analyze test/field data, generate reliability reports, and communicate findings to drive design and process improvements.
• Familiarity with electronics & controls (sensors, HMIs, drives), electro-mechanical interactions, and manufacturing processes affecting reliability.