Sr. Process Engineer

Reposted 6 Days Ago
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Burlington, MA, USA
In-Office
97K-162K Annually
Senior level
Other • Security
The Role
Lead process development to take new thermal management products from lab to mass production. Design experiments, characterize materials, troubleshoot and optimize prototype and production equipment, build test rigs, perform FMEA and risk assessments, analyze data to improve quality and throughput, and collaborate cross-functionally in a fast-paced, on-site environment.
Summary Generated by Built In

Build your best future with the Johnson Controls team!

Who we are:

Johnson Controls is global leader in smart, healthy, and sustainable buildings. Our mission is to reimagine the performance of buildings to serve people, places, and the planet. Join a winning team that enables you to build your best future! Our teams are uniquely positioned to support a multitude of industries across the globe. You will have the opportunity to develop yourself through meaningful work projects and learning opportunities. We strive to provide our employees with an experience focused on supporting their physical, financial, and emotional wellbeing. Become a member of the Johnson Controls family and thrive in an empowering company culture where your voice and ideas will be heard – your next great opportunity is just a few clicks away!

What We Offer:

  • Competitive salary

  • Paid vacation/holidays/sick time

  • Comprehensive benefits package including 401K, medical, dental, and vision care.

  • On-the-job/cross-training opportunities

  • Encouraging and collaborative team environment

  • Dedication to safety through our Zero Harm policy

Thermal constraints limit AI infrastructure, semiconductor equipment, power electronics, and defense systems. JCI removes those constraints. Enabled by the Stack Forging™ process, JCI produces high-performance thermal components and cooling loop solutions — purpose-built for direct integration into AI, HPC, and mission-critical systems. JCI has built the industry's leading thermal management platform for the applications that demand it most. 

As a Builder on the Stack Forging Thermal Solutions team at Johnson Controls, you'll join a team of sleeve-rollers who set a high bar for themselves and their co-workers. We foster a collaborative culture with no silos, where everyone is encouraged to think out loud. If you are passionate about your craft and don't give up until you've found a way, you will make an ideal Builder! 

 

What You’ll Do 

As a Sr. Process Engineer, New Product Introduction, you will work on engineering efforts to bring products from the lab into mass production. Your primary objective is to rapidly iterate and advance to ensure the product is manufacturable, cost-effective, meets quality standards, and meets all requirements before launch to market.  

Who You Are 

A successful candidate is a hands-on and creative problem-solver eager to take on complex technical challenges. You will be a key contributor across multiple steps of our manufacturing process, which includes areas such as laser cutting, metal-metal bonding, surface characterization/preparation, complex part geometry design, advanced data and computational analysis, and material property optimization. You will be expected to independently lead projects from initial concept and ideation, through rigorous data collection and analysis, and ultimately to successful handoff to production machines, resulting in parts that go directly to our customers. 

 

This role requires a high degree of technical ownership, cross-functional collaboration, critical thinking for root cause analysis, and an ability to thrive in a fast-paced environment. This position generally requires a commitment of 5 days onsite per week. 

 

Responsibilities 

*Responsibilities are subject to change based on shifting business needs 

  • Lead cross-functional engineering projects by defining scope and priorities, managing technical timelines, and presenting results across the organization. 

  • Proactively identify and debug complex process issues, brainstorm potential fixes, design and execute experiments to test effectiveness, and implement robust, long-term solutions. 

  • Work collaboratively with design, materials, and hardware teams to problem-solve and ensure all design and functional constraints are considered in the process. 

  • Perform thorough root cause analysis on parts and processes. 

  • Assemble and present detailed experimental results and technical findings to both technical and non-technical team members and leadership. 

  • Design, implement, and maintain inline inspection and data collection systems to monitor and control 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 that contribute to the next generation of our manufacturing platform. 

 

Qualifications 

  • Technical degree (BS/MS) with 7+ years of industry experience, or a PhD with 3+ years of industry experience in Mechanical Engineering, System Engineering, Electrical Engineering, Controls Engineering, Advanced Manufacturing, or a related field. 

  • Proven ability to rapidly iterate and improve process methods to significantly enhance throughput, yield, and reliability in a manufacturing environment. 

  • Systems level thinking to understand the tradeoffs multiple process steps  

  • Deep experience with at least one of the following: imaging processing, in-line inspection and metrology, automation, hardware design, instrumentation and control systems, machine bring-up and validation, or advanced statistical data analysis. 

  • Excellent communication skills, both written and verbal, with a demonstrated ability to effectively interpret and present complex technical data. 

  • A 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, ambiguous challenges. 

 

Preferred Qualifications 

  • Proficiency with Python software coding in a data analysis and automation context. 

  • Readiness and enthusiasm to work in a dynamic environment that features: rapidly changing requirements, quick iteration with novel hardware, heavy communication demands, and process development that involves critical, high-risk trade-offs. 

  • Dynamic and flexible mindset, easily balancing the immediate needs of the day-to-day with long-term strategic thinking and planning. 

 

SALARY RANGE: $97,000 - $162,000 (Salary to be determined by the education, experience, knowledge, skills, and abilities of the applicant, internal equity, 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. The posted salary range reflects the target compensation for this role. However, we recognize that exceptional candidates may bring unique skills and experiences that exceed the typical profile. If you believe your background warrants consideration beyond the stated range, we encourage you to apply. To support an efficient and fair hiring process, we may use technology assisted tools, including artificial intelligence (AI), to help identify and evaluate candidates. All hiring decisions are ultimately made by human reviewers. For details, please visit the About Us tab on the Johnson Controls Careers site at https://jobs.johnsoncontrols.com/about-us

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. To view more information about your equal opportunity and non-discrimination rights as a candidate, visit EEO is the Law. If you are an individual with a disability and you require an accommodation during the application process, please visit here.

Skills Required

  • Bachelor's degree in mechanical, materials, systems, chemical engineering or similar discipline
  • 2-4 years of experience, preferably in advanced manufacturing or with precision/industrial equipment
  • Hands-on experience working directly with industrial equipment
  • Experience working with pilot or production machines
  • Basic programming and data analysis skills
  • Readiness and enthusiasm to work in a dynamic, rapidly changing environment
  • Dynamic and flexible mindset balancing immediate needs with long-term planning
  • Excellent written and verbal communication skills and ability to present complex technical data

Johnson Controls Compensation & Benefits Highlights

The following summarizes recurring compensation and benefits themes identified from responses generated by popular LLMs to common candidate questions about Johnson Controls and has not been reviewed or approved by Johnson Controls.

  • Retirement Support Retirement support is positioned as a meaningful part of the package through employer 401(k) matching, repeatedly framed as a strong pillar of the overall rewards mix. The matching contribution is described with specific match levels in multiple places, reinforcing perceived value for long-term saving.
  • Leave & Time Off Breadth Time off is presented as comparatively robust, with multiple paid holiday categories, vacation time, and sick time described as generous or “amazing” in places. Paid time off breadth appears to be a consistent contributor to total rewards attractiveness beyond base pay.
  • Flexible Benefits Benefits are described as broad and customizable, spanning standard medical/dental/vision plus optional add-ons like pet insurance, identity protection, and legal support. Tuition reimbursement is repeatedly highlighted as a high-value option supporting professional development.

Johnson Controls Insights

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The Company
HQ: Chennai
100,000 Employees
Year Founded: 1885

What We Do

At Johnson Controls, we transform the environments where people live, work, learn and play. From optimizing building performance to improving safety and enhancing comfort, we drive the outcomes that matter most. Dedicated to protecting the environment, we deliver our promise in industries such as healthcare, education, data centers and manufacturing. With a global team of 100,000 experts in more than 150 countries and over 130 years of innovation, we are the power behind our customers’ mission. Our leading portfolio of building technology and solutions includes some of the most trusted names in the industry, such as Tyco®, York®, Metasys®, Ruskin®, Titus®, Frick®, Penn®, Sabroe®, Simplex®, Ansul® and Grinnell®.

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