Lean Manufacturing Engineer

Johnson Controls; San Antonio (TX); On-site; USD 76,000 - 114,000; Full time

Benefits offered by this job

Competitive salary

Vacation & holidays

Benefits package

On-the-job training

Collaborative team

Safety policy

Job summary

Johnson Controls in Texas seeks a manufacturing process engineer to develop and optimize production methods for current and new products. You will design layouts, tooling and documentation, applying Lean methods to improve efficiency and reduce waste.

The role emphasizes capital project leadership, manufacturability assessments, and cross-functional collaboration, with a strong focus on safety and quality. A BS in mechanical or industrial engineering is required, with 5 years' experience.

Qualifications

• Bachelor of Science in Mechanical or Industrial Engineering with 5 years in assembly/process development.
• Proficient with AutoCAD and MS Office; Lean Manufacturing expertise.
• Knowledge of tooling/fixtures design, Six Sigma, MSA and capability studies.
• Strong written and verbal communication; good organizational and PM skills.
• Experience implementing process improvements and designing manufacturability reviews.

Responsibilities

• Develop, evaluate and improve manufacturing methods to sustain existing products and enable new ones.
• Design layouts, tooling, fixturing, gauging, programming, and documentation.
• Lead Lean initiatives and cost-reduction, Kaizen, and safety projects.
• Provide technical troubleshooting in production and support capital equipment projects.
• Assess new product concepts for manufacturability and communicate with R&D/Engineering.
• Drive process design and documentation to meet quality, cost, and timeline targets.
• Collaborate with cross-functional teams to ensure smooth implementation.

Skills

Lean Manufacturing

AutoCAD

Six Sigma

MS Office

Tooling & fixtures

Project management

Communication

Education

Bachelor of Science in Mechanical or Industrial Engineering

Tools

Simulation software

CNC equipment

Job 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.

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 and annual bonus
• Paid vacation/holidays/sick time
• Comprehensive benefits package including 401K, medical, dental, and vision care - available day one
• On the job/cross training opportunities
• Encouraging and collaborative team environment
• Dedication to safety through our Zero Harm policy

What You Will Do

You will work with a tem of seven people to develop, evaluate, and improve manufacturing methods and processes for the purpose of sustaining the manufacture of existing products as well as the introduction of new products.

How You Will Do It

• Conduct detailed process design work, including layouts, tooling, fixturing, gauging, programming, and documentation. 30%
• Continuously improve current production methods using Lean Manufacturing methodologies and utilizing knowledge of product design, materials and parts, fabrication processes, tooling, and production equipment capabilities, assembly methods and quality control standards. 20%
• Provide technical know-how to troubleshoot problems in current production 10%
• Initiate and lead capital equipment projects. 10%
• Lead Cost-Reduction, Safety, Kaizen, and other initiatives. 10%
• Assess new product concepts and designs for manufacturability and provide such assessment and recommendations to R&D/Product Engineering. 10%
• Conceive methods and processes to manufacture new products in the safest manner, at the desired quality standards, and at the lowest cost to meet projected demand in a timely manner. 5%
• Conduct proof of principle or proof of concept studies. 5%

Required

What we look for:

• Bachelor of Science degree in one of the following fields of study: Mechanical Engineering or Industrial Engineering and 5 years of relevant experience supporting assembly operations inclusive of experience in process development documentation, time standards, workflow analysis, ergonomics, work fixture design, and continuous improvement
• Proficient with use of computer and software applications including MS Office products and AutoCAD
• Proficient in Lean Manufacturing
• Tooling & fixture design experience.
• Understanding any Simulation software
• Understanding of tooling, gauging, Six Sigma, MSA, and capability studies.
• Excellent communication skills, both verbally and in writing and be able to read and write business policies, procedures, general business periodicals, manuals, part drawings and other correspondence.
• Must have strong organizational and project management skills.

Preferred

• Experience in ASME welding techniques and requirements.
• Experience in supporting operations using torque equipment.
• Experience in supporting operations using welding equipment.
• Experience in supporting operations using CNC tube bending equipment.
• History of process improvements and new process design based on advancements in technology and changing environment of manufacturing.
• Black Belt Six Sigma (DMAIC) certification.
• Experience in concurrent engineering environment will be a plus.

Hiring Salary Range

$76,100.00 - $114,100.00 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 position includes a competitive benefits package. For details, please visit the About Us tab on the Johnson Controls Careers site at https://jobs.johnsoncontrols.com/about-us

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