Sr Advanced Manufacturing Engineer

About Johnson Controls

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.

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Senior Advanced Manufacturing Engineer

Location: San Antonio, TX

The Senior Advanced Manufacturing Engineer is responsible for the development, industrialization, installation, commissioning, and continuous improvement of manufacturing systems, equipment, and facilities. This role leads capital investment projects from concept through production launch, managing equipment suppliers, budgets, procurement activities, manufacturing process design, and cross-functional execution.

The position serves as the technical and program management lead for new production lines, manufacturing facility expansions, automation projects, and plant start-ups. The engineer collaborates closely with Engineering, Operations, Quality, Supply Chain, Procurement, Materials, Testing, Maintenance, EH&S, and external suppliers to ensure projects are delivered safely, on schedule, within budget, and capable of meeting operational performance targets.

Key Responsibilities

• Manufacturing Equipment Development & Industrialization
• Lead the specification, design, development, sourcing, installation, and commissioning of manufacturing equipment and production systems.
• Develop equipment Statements of Work (SOW), technical specifications, RFQs, and supplier selection criteria.
• Oversee machine design reviews, Factory Acceptance Tests (FAT), and Site Acceptance Tests (SAT).
• Support equipment debugging, troubleshooting, process validation, and production ramp-up activities.
• Drive automation initiatives to improve safety, productivity, ergonomics, and quality.
• Establish equipment performance metrics including OEE, cycle time, uptime, scrap rates, and throughput.

Capital Projects (CAPEX) Management

• Develop and manage manufacturing CAPEX budgets and project financials.
• Build business cases and ROI analysis for equipment and facility investments.
• Manage project schedules, milestones, risk registers, and implementation plans.
• Track project expenditures and ensure adherence to approved budgets.
• Coordinate facility readiness activities including utilities, infrastructure, safety systems, and production support functions.
• Lead capital project reviews with Finance, Operations, and Executive Leadership.
• Procurement & Supplier Management
• Develop RFQs and participate in supplier evaluation and selection activities.
• Generate and manage Purchase Requisitions (PRs) and Purchase Orders (POs).
• Negotiate technical deliverables, project milestones, and acceptance criteria with suppliers.
• Act as the primary program manager for supplier deliverables and payment milestones.
• Monitor invoice approval processes and coordinate with Procurement and Finance to ensure timely supplier payments.
• Conduct regular supplier performance reviews and corrective action follow-up.

New Manufacturing Facility Development

• Support planning and execution of new manufacturing facilities, plant expansions, and production transfers.
• Develop facility layouts considering material flow, safety, labor efficiency, logistics, and future growth requirements. Define manufacturing space requirements for:
• Production lines, Warehousing, Material supermarkets, Quality laboratories, Engineering areas, Maintenance shops, Training centers, Office spaces, Coordinate facility infrastructure requirements including:
• Electrical systems, Compressed air, Cooling water systems, Process water systems, Environmental controls, HVAC, Fire protection systems, Utility distribution networks, Manufacturing Process Development.
• Design and implement assembly and manufacturing processes for new products and production systems.
• Perform line balancing studies to optimize labor utilization and throughput.
• Develop standard work instructions and manufacturing methods.
• Conduct capacity analysis and resource planning.
• Lead PFMEA activities and process risk assessments.
• Define tooling, fixtures, and error-proofing solutions (Poka-Yoke).
• Support process capability studies and production validation activities.

Material Handling & Factory Flow

• Design material flow strategies to support lean manufacturing principles.
• Specify and implement material handling equipment including:
• Conveyors, AGVs/AMRs, Lift assists, Cranes and hoists, Storage systems
• Kitting solutions
• Flow racks
• Develop future-state factory layouts using AutoCAD and Factory Flow simulation tools.
• Optimize warehouse-to-line material replenishment systems.
• Technical Leadership

Ideally Provide technical expertise in:

• Welding processes, Resistance welding, MIG/TIG welding, Structural fabrication, Electrical systems, Control systems integration, Pneumatic systems
• Hydraulic systems, Pressure vessel manufacturing, Water management and cooling systems, Automated assembly systems, Industrial machinery installation, Manufacturing safety standards, Cross-Functional Collaboration

Required Qualifications

• BS in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Mechatronics Engineering, Electrical Engineering.
• Equivalent technical discipline Experience
• 8+ years of manufacturing engineering experience.
• 5+ years managing equipment development and industrialization projects.
• Demonstrated experience launching new manufacturing lines and facilities.
• Experience managing multimillion-dollar CAPEX projects.
• Experience working with equipment suppliers from concept through production launch.
• Experience managing procurement activities, POs, payment milestones, and supplier performance. Hands-on experience with manufacturing equipment commissioning and startup.

Preferred Qualifications

• PMP (Project Management Professional), Lean Six Sigma Green Belt or Black Belt
• Experience in automotive, HVAC, industrial equipment, pressure vessels, robotics, or automation industries
• Experience supporting greenfield manufacturing facility development.

HIRING SALARY RANGE: $90,000 - $125,000 (Salary to be determined by the education, experience, knowledge, skills, and abilities of the applicant, internal equity, and alignment with market data.) 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.