Mfg Product Engineer Sr.

Description

About Us

Johnson Controls, a global leader in thermal management, mission-critical building systems, energy efficiency, and decarbonization, helps customers use energy more productively, reduce carbon emissions, and operate with the precision and resilience required in rapidly expanding industries such as data centers, healthcare, pharmaceuticals, advanced manufacturing, and higher education.

For more than 140 years, Johnson Controls has delivered performance where it really matters. Backed by advanced technology, lifecycle services and an industry-leading field organization, we elevate customer performance, turn goals into real-world results and help move society forward.

What we offer

• Competitive salary

• Paid time off: 15 days’ paid vacation/10 days’ paid holidays/5 sick days each calendar year

• Comprehensive benefits package including 401(k) with company match, medical, dental, and vision care – all available day one of employment

• Encouraging and collaborative team environment

• Dedication to safety through our Zero Harm policy

What you will do

You will be responsible for improving, maintaining, and supporting all automated Assembly, Test, and Production systems within the facility. You will also focus on increasing equipment performance, reliability, OEE, and process capability by providing advanced technical expertise in automation, PLC programming, industrial controls, robotics, data acquisition, and troubleshooting.

This role supports new equipment installations while prioritizing optimization of existing assets, ensuring they operate safely, consistently, and at required production rates. You will also work closely with Operations, Maintenance, Quality, Product Engineering, and Process Engineering to drive continuous improvement and deliver sustainable automation solutions.

How you will do it

Equipment Performance & Reliability

• Improve performance, uptime, and reliability of automated Assembly and Testing equipment.

• Lead troubleshooting of complex automation issues, including PLC logic, sensors, communications, HMIs, robotics, and servo/motion systems.

• Conduct root cause analysis for recurring equipment failures and implements permanent corrective actions. Drive improvements to eliminate unplanned downtime and reduce cycle time variability.

2. PLC, Controls, and Software Development

• Develop, modify, optimize, and maintain PLC programs (Allen‑Bradley / Siemens or plant standards).

• Update and improve HMI screens, diagnostics, alarm structures, and operator interfaces.

• Maintain robust version control and documentation for all automation code.

• Implement and maintain error‑proofing (Poka‑Yoke) logic to prevent product or process defects.

3. OEE Improvement & Automation Optimization

• Own OEE improvement initiatives for automated lines—Availability, Performance, Quality.

• Analyze performance data and downtime trends to target improvement opportunities.

• Optimize machine motion profiles, cycle times, process sequences, and control logic.

• Support Process Engineering in eliminating bottlenecks and improving takt adherence.

4. New Equipment & Technology Integration

• Lead automation-related activities for new equipment: specification, vendor management, design reviews, and commissioning.

• Develop functional specifications, control architecture, and FAT/SAT acceptance criteria.

• Support equipment buyoffs, debugging, installation, and process validation.

• Identify and deploy new technologies to improve automation capability and efficiency.

5. Documentation & Change Management

• Maintain updated electrical schematics, I/O lists, network diagrams, and device documentation.

• Support ECNs/ECRs with required automation changes and proper documentation.

• Create and maintain technical documentation for operators, Maintenance, and Engineering teams.

6. Continuous Improvement & Process Support

• Participate in and lead CI/Kaizen events targeting uptime, scrap, cycle-time reduction, and throughput improvement.

• Implement data collection, system monitoring, and analytics tools to enhance decision making.

• Collaborate with Process Engineering on workflow, line balance, and layout improvements.

7. Testing Systems & Instrumentation

• Maintain, troubleshoot, and improve automated test equipment, instrumentation, and data acquisition systems.

• Ensure test systems meet capability, repeatability, and calibration requirements.

• Enhance diagnostic features to speed up troubleshooting and reduce false failures.

8. Cross‑Functional Collaboration

• Work closely with Quality to improve test capability, Poka‑Yoke coverage, and error detection systems.

• Assist Operations in resolving daily automation issues and supporting production recovery efforts.

• Partner with Maintenance to ensure reliable, safe, and sustainable operation of automation systems.

• Perform other duties as assigned.

What we look for

Required:

• Bachelor’s degree in Electrical Engineering, Mechatronics, Automation Engineering, or related field.

• Hands‑on experience with PLC programming (Allen‑Bradley preferred), HMIs, sensors, robotics, motions systems, and industrial networks.

• Strong troubleshooting skills and experience with automated production equipment.

• Ability to analyze equipment data and drive improvements in OEE and machine reliability.

• Understanding of electrical schematics, controls design, and machine safety standards.

• Familiarity with Lean manufacturing principles and continuous improvement.

• Advanced troubleshooting and problem solving

• Automation controls & programming

• Cross‑functional collaboration

• Root cause analysis (RCA)

• Lean manufacturing / continuous improvement principles

• Project management

• Strong documentation and communication skills

• Ownership mindset and accountability

HIRING SALARY RANGE: $85,200.00 - $127,800.00 USD Annual (Salary to be determined by the education, experience, knowledge, skills, and abilities of the applicant, internal equity, location and alignment with market data). This role offers a competitive Bonus plan that will take into account individual, group, and corporate performance. This position includes a competitive benefits package. For details, please visit the About Us tab on the Johnson Controls Careers site at .

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Johnson Controls International plc. is an equal employment opportunity and affirmative action employer and all qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, age, protected veteran status, genetic information, sexual orientation, gender identity, status as a qualified individual with a disability or any other characteristic protected by law.