Senior Manufacturing Engineer

Johnson Controls is a global leader in smart, healthy, and sustainable buildings. With operations in over 150 countries, we are committed to driving innovation and excellence in building technologies and integrated solutions. Our people are at the heart of our success, and we are passionate about attracting and developing top talent across the globe.

Position Summary

The Senior Manufacturing Engineer is responsible for leading the design, implementation, optimization, and expansion of manufacturing processes and production lines in a world-class manufacturing environment. This role drives operational excellence through Lean Manufacturing principles and strategic project management. The ideal candidate will have strong ability in Industrial Engineering, capacity expansion, line balancing, facility layout optimization, and new production line implementation.

What will you do?

Project Management

• Lead manufacturing projects from concept development through implementation and stabilization.
• Develop project plans, timelines, budgets, risk assessments, and resource allocation strategies.
• Coordinate cross-functional teams to ensure successful project execution.
• Manage capacity expansion, automation, and process transfer projects.
• Apply PMP, PMBOK, Agile, and/or Scrum methodologies to deliver projects on time and within budget.

Manufacturing Line Design & Implementation

• Design and launch new production lines based on Lean Manufacturing principles.
• Develop efficient material and information flow systems to maximize productivity.
• Define equipment, manpower, tooling, and capacity requirements.
• Establish standardized work, visual management systems, and operational procedures.
• Implement Pull Systems, Kanban, Heijunka, Just-in-Time (JIT), and Continuous Flow concepts.

Industrial Engineering & Continuous Improvement

• Conduct time studies and motion analysis.
• Perform line balancing to optimize labor utilization and productivity.
• Calculate and monitor key manufacturing metrics such as Takt Time, Cycle Time, OEE, Throughput, and Capacity Utilization.
• Identify and eliminate waste using Lean methodologies and structured problem-solving tools.
• Lead Kaizen events, Value Stream Mapping (VSM), A3 Problem Solving, and continuous improvement initiatives.
• Apply Six Sigma methodologies to reduce variation and improve process capability.

Capacity Planning & Plant Layout Optimization

• Develop and execute capacity expansion strategies to support business growth.
• Lead plant layout redesign and facility optimization projects.
• Analyze current and future manufacturing capacity requirements.
• Design manufacturing cells and efficient production flows.
• Optimize factory floor utilization, material handling, and logistics operations.

Process Simulation & Manufacturing Design

• Develop production simulations and capacity models using FlexSim.
• Evaluate manufacturing scenarios and bottlenecks through simulation tools.
• Design tooling, fixtures, workstations, and manufacturing equipment using SolidWorks and AutoCAD.
• Create and maintain 2D and 3D facility layouts and manufacturing line designs.

What are we looking for?

Education

• Bachelor’s Degree in Industrial Engineering, Manufacturing Engineering, Mechanical Engineering, Mechatronics Engineering, or related field.
• Master’s Degree in Engineering, Operations Management, Business Administration, or Project Management is preferred.

Experience

• Minimum of 8 years of experience in Manufacturing Engineering, Industrial Engineering, or Operations.
• Proven experience designing and launching manufacturing lines from concept to production.
• Demonstrated success in capacity expansion and productivity improvement projects.
• Experience leading major plant layout modifications and facility expansion initiatives.
• Experience in high-volume manufacturing environments.
• Strong background implementing Lean Manufacturing principles.

Technical Knowledge & Skills

• Lean Manufacturing
• Value Stream Mapping (VSM)
• Kaizen
• Kanban
• Heijunka
• SMED
• Andon
• Jidoka
• Poka-Yoke
• Standardized Work
• 5S
• OEE
• Root Cause Analysis
• Industrial Engineering
• Line Balancing
• Time and Motion Studies
• Capacity Planning
• Ergonomics
• Process Design
• Material Flow Analysis
• Plant Layout Design
• Resource Optimization
• Manufacturing Performance Metrics
• Project Management
• PMBOK Methodology
• Agile Project Management
• Scrum Framework
• Budget Management
• Risk Management
• Stakeholder Management
• Software SolidWorks (Advanced)
• AutoCAD (Advanced)
• FlexSim (Advanced)
• Microsoft Project
• Advanced Microsoft Excel Power BI (Preferred)
• Minitab (Preferred)

Preferred Certifications

• Project Management PMP (Project Management Professional)
• Certified Scrum Master (CSM) Continuous Improvement Lean Six Sigma Black Belt

Core Competencies

• Strong leadership and project management skills.
• Strategic and analytical thinking.
• Results-oriented mindset.
• Structured problem-solving capabilities.
• Change management and organizational influence.
• Data-driven decision making.
• Strong communication and presentation skills.
• Ability to lead cross-functional teams in a fast-paced manufacturing environment.
• High level of accountability and ownership.

Key Performance Indicators (KPIs)

• Production capacity increase.
• Manufacturing cost reduction.
• Productivity and Efficiency.
• Lead time reduction.
• OEE improvement.
• Project delivery performance (on-time and on-budget).
• Lean savings and cost avoidance.
• Space utilization efficiency.
• Scrap and waste reduction.
• Project ROI achievement.

What do we offer?

• Comprehensive benefits package.
• Opportunities for professional growth and development.
• Supportive and inclusive work environment.
• Commitment to work-life balance and employee well-being.
• Engagement in meaningful projects that make a difference.

Johnson Controls does not request pregnancy or HIV testing as a condition for hiring, continued employment, or promotion, in accordance with its commitment to labor equality and non-discrimination.

Johnson Controls: Enhancing the Intelligence of Buildings Your buildings have a purpose. They are places for people to live or work. Facilities for learning or healing. Venues for entertainment and shopping. Sites for the specialized storage of tangible goods or mission-critical data. Your buildings have a huge variety of functions; they are central to your mission. This is where Johnson Controls comes in, helping drive the outcomes that matter most. Through a full range of systems and digital solutions, we make your buildings smarter. A smarter building is safer, more comfortable, more efficient, and, ultimately, more sustainable. Most important, smarter buildings let you focus more intensely on your unique mission. Better for your people. Better for your bottom line. Better for the planet. At Johnson Controls, we've been making buildings smarter since 1885, and our capabilities, depth of innovation experience, and global reach have been growing ever since. Today, we offer the world's largest portfolio of building products, technologies, software, and services; we put that portfolio to work to transform the environments where people live, work, learn and play.