Senior Process & Automation Engineer (PLC, Robotics & Manufacturing)

Johnson Electric Group; Tennessee; On-site; USD 110,000 - 150,000; Full time

Benefits offered by this job

Competitive pay and benefits

Job summary

Johnson Electric is seeking a Senior Process & Automation Engineer to lead the design, development, implementation, validation, and continuous improvement of high‑volume automotive manufacturing processes.

You will serve as the technical advisor, guiding cross‑functional teams while supporting new product launches, automation initiatives, robotics integration, PLC‑controlled equipment, and Industry 4.0 technologies.

Qualifications

• Bachelor’s degree in mechanical, industrial, or manufacturing engineering required.
• Minimum 5+ years in automotive or advanced manufacturing engineering.
• Proven experience leading manufacturing improvement projects.
• Knowledge of Lean, Six Sigma, and continuous improvement methodologies.
• Experience with capital equipment procurement and implementation.

Responsibilities

• Lead design, development, implementation, validation, and ongoing improvement of manufacturing processes.
• Act as technical advisor for manufacturing processes and guide cross-functional teams.
• Mentor engineers and technicians; lead complex projects and process standardization.
• Drive continuous improvement and inspect process capability (Cp/Cpk), DOE, and statistical analyses.
• Lead automation projects including PLCs, robotics, vision systems, and Industry 4.0 initiatives.

Skills

Lean

Six Sigma

Problem solving

Analytical skills

Mentoring & coaching

Cross-functional collaboration

Strong communication

Education

Bachelor’s degree in mechanical engineering, industrial engineering, or manufacturing engineering

Tools

Keyence cameras & scanner systems

APQP

PFMEA

Control Plans

SPC

MSA

Job description

As our next Senior Process & Automation Engineer, you are responsible for leading the design, development, implementation, validation, and continuous improvement of manufacturing processes that deliver world-class safety, quality, productivity, and cost performance in a high-volume automotive manufacturing environment. This role serves as the technical advisor for manufacturing processes, providing suggestions and direction to cross-functional teams while supporting new product launches, automation initiatives, robotics integration, PLC-controlled equipment, and advanced manufacturing technologies.

The Senior Process Engineer partners closely with Production, Quality, Maintenance, Supply Chain, and Product Engineering to develop robust manufacturing systems that meet IATF 16949, VDA 6.3, customer-specific requirements, and operational excellence objectives. This position is expected to mentor engineers and technicians, lead complex manufacturing projects, drive process standardization, and champion continuous improvement initiatives throughout the product lifecycle.

NOTE: This is not a direct report position. All candidates must be able to work for any employer in the United States without visa sponsorship.

Why You’ll Love Working Here

• Lead high-impact manufacturing and automation projects.
• Work with robotics, PLCs, machine vision and Industry 4.0 technologies.
• Collaborate with global cross-functional teams.
• Drive operational excellence and continuous improvement.
• Mentor engineering talent.

What You’ll Be Doing

• Serve as the technical advisor for manufacturing processes, providing guidance and direction to engineers, technicians, and cross-functional teams.
• Help guide multidisciplinary teams during new product launches, automation projects, and major manufacturing improvements.
• Mentor and develop Process Engineers, and Engineering Technicians through coaching and knowledge sharing.
• Drive a culture of continuous improvement, accountability, and operational excellence across manufacturing operations.
• Develop, implement, and optimize manufacturing processes
• Analyze production data and implement corrective actions
• Maintain process documentation (work instructions, SOPs)
• Collaborate with Quality, Production, and Maintenance teams
• Support new equipment installation and process improvements
• Monitor process KPIs (scrap, yield, cycle time)
• Participate in audits and compliance activities
• Lead automation projects including specification, design review, implementation, commissioning, and validation of manufacturing equipment.
• Support integration of PLCs, robotics, machine vision, sensors, poka-yoke systems, and Industry 4.0 technologies. Collaborate with automation suppliers and system integrators to ensure successful project execution.
• Develop manufacturing strategies that improve safety, quality, productivity, and profitability.
• Lead process design reviews and manufacturability (DFM/DFA) assessments for new product introductions.
• Establish and maintain standardized manufacturing methods across production lines.
• Lead process capability studies (Cp/Cpk), DOE activities, and statistical analysis to optimize manufacturing performance.
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What We’re Looking For

• Bachelor’s degree in mechanical, Industrial, or Manufacturing Engineering
• Knowledge in Keyence Cameras and Scanner systems
• 5+ years of experience in automotive manufacturing or advanced manufacturing engineering
• Knowledge of Lean, Six Sigma, and continuous improvement methodologies
• Experience with APQP, PFMEA, Control Plans, SPC, and MSA
• Strong problem-solving and analytical skills
• Proven experience leading manufacturing improvement projects.
• Experience advising and assist in guiding cross-functional teams.
• Experience managing automation suppliers and equipment integrators.
• Experience with capital equipment procurement and implementation.
• Strong knowledge in balancing concepts and functionality (static, dynamic) is a plus
• Leads by Example
• Experience developing others through coaching and mentoring.
• Influences without authority.
• Makes sound technical decisions under pressure.
• Builds high-performing cross-functional teams.
• Drives accountability and execution.
• Champions innovation and continuous improvement.
• Effectively communicates with all organizational levels.

Bonus Points if you have:

• Knowledge in 6 Axis Kuka Robots and AI vision systems
• Strong knowledge in balancing concepts and functionality (static, dynamic)

What we offer:

Johnson Electric offers talented people like you the opportunity to grow professionally and personally, surrounded by some of the most dedicated, innovative, and entrepreneurial colleagues you will find anywhere. Of course, we offer competitive pay and benefits, and far more than that, we offer you a culture driven by our values and designed to ensure that our most important asset—our people—can flourish. Johnson Electric welcomes and encourages applications from people with disabilities. Accommodations are available on request for candidates taking part in all aspects of the selection process.

In accordance with the Ontario Human Rights Code and the Accessibility for Ontarians with Disabilities Act, Johnson Electric is an equal opportunity employer who is committed to providing an inclusive and barrier free recruitment and selection process. Applicants should advise Human Resources if they require any type of accommodation during the recruitment process.

Please note: Johnson Electric may use Artificial Intelligence (AI) tools as part of our process.