Role Overview
The Sr. Quality Engineer serves as a technical leader within the Johnson Controls Chillers manufacturing facility, driving product and process quality while ensuring adherence to the Quality Management System (QMS). This position operates in a fast‑paced, low‑mix production environment characterized by demanding customer timelines, active NPI/ECN activity, and complex electromechanical assemblies.
This role leads root cause investigations, APQP activities, supplier quality escalations, and data‑driven improvement initiatives aimed at increasing First Pass Yield (FPY), reducing customer escapes, minimizing scrap. Close collaboration with Operations, Engineering, and Global Quality is essential to maintaining robust processes and delivering flawless products.
Key Responsibilities
QMS & Compliance
- Support the upkeep and effectiveness of the site QMS in accordance with ISO 9001 and internal requirements.
- Participate in internal and external audits; lead corrective actions and ensure timely closure of findings.
- Maintain and update documented information, including procedures, work instructions, control plans, and PFMEAs.
Production Quality Performance
- Lead daily quality engineering activities for in‑process and final inspections.
- Develop initiatives to strengthen our testing capabilities and implement CTQ and SPC on the assembly lines
- Ensure the implementation of a robust control plan and PFMEA across the assembly lines
- Manage the daily review board, including defect analysis, dispositions, and nonconforming material documentation.
- Drive systemic corrective actions using 8D, A3, DMAIC, or similar methodologies.
Supplier Quality Collaboration
- Partner with Supplier Development & Performance (SD&P) and Supplier Quality Engineering (SQE) to resolve supplier‑related issues and support 8D responses.
NPI / Engineering Change
- Ensure Engineering Change Notices (ECNs) are implemented with appropriate risk assessment, verification, and documentation updates.
- Work closely with Engineering to ensure manufacturability and strong design/process controls.
Systems & Data
- Use enterprise QMS and issue‑tracking systems to document and resolve issues.
- Analyze quality data and develop dashboards for FPY, scrap, and other key metrics.
- Ensure data accuracy and leverage analytics to identify trends and improvement opportunities.
Cross‑Functional Collaboration & Communication
- Provide clear updates on quality performance, risks, and improvement actions to the Plant Quality Manager and operations leadership.
- Participate in tiered meetings and support decision‑making with data‑driven insights.
- Prepare concise reports, presentations, and technical summaries for internal stakeholders.
Culture & Continuous Improvement
- Champion a Zero Harm and quality‑first culture across the plant.
- Mentor junior engineers and quality auditors; support training on quality tools, standards, and audit readiness.
Required Qualifications
- Bachelor’s degree in Engineering, Quality, or a related discipline.
- 3–5+ years of experience in manufacturing quality engineering.
- Strong knowledge of PFMEA, Control Plans, MSA, SPC, and structured problem‑solving tools (8D, DMAIC, A3).
- Proficiency in data analysis, capability indices, and dashboard/report creation.
- Excellent communication and cross‑functional collaboration skills.
Preferred Qualifications
- Experience in HVAC (Highly desirable), automotive, or electromechanical manufacturing.
- Certifications such as Six Sigma Green/Black Belt, ISO 9001 Internal Auditor, or GD&T (Highly desirable).
- Bilingual capabilities (Local language and spanish).
Key Performance Indicators (KPIs)
- First Pass Yield (FPY) and Defects Per Unit (DPU/DPMO).
- Scrap performance.
- Audit finding closure time and QMS compliance metrics.
- Ensure ongoing compliance and continuous updates of the Control Plan and PFMEA.
Key Interfaces
- Plant Manager, Operations, Materials, Engineering, Maintenance, EHS.
- Supplier Development & Performance (SD&P), Supplier Quality Engineering (SQE), Procurement.
Work Environment & Travel
This role is based onsite at the Johnson Controls San Antonio plant, requiring daily presence on the shop floor. Occasional travel to other Johnson Controls facilities may be required.
HIRING SALARY RANGE: $85,000-$117,000 (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
