Sr. Process Engineer

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."

Sr. Process Engineer, Delivery

Cooling performance limits AI infrastructure, semiconductor equipment, photonics, power electronics, defense systems, and other high-powered compute applications.

Alloy Enterprises addresses these constraints with advanced thermal management components enabled by its Stack Forging™ process, which creates single-piece, leak-tight metal parts with complex internal microgeometries for stronger cooling performance, lower pressure drop, and high reliability.

Founded in 2020, Alloy has built an industry-leading thermal management platform for data centers and mission-critical systems.

This role generally requires 4 days onsite per week.

What You’ll Do

As a Sr. Process Engineer, Delivery, you will work on engineering efforts enabling the delivery of high-performance, high-quality parts to Alloy’s customers ahead of schedule. Your primary objective is to provide process expertise throughout production, ensuring that our thermal management solutions meet exacting standards through rigorous process tuning and hands-on problem-solving.

Who You Are

You are a resilient, tenacious engineer with a deep sense of ownership. Identifying and dismantling roadblocks is your core competency. You are comfortable navigating a high-growth environment and possess the technical grit and engineering judgment necessary to deliver. You will be the vital link that ensures we deliver successful customer outcomes while pushing the limits of the Stack Forging process.

Responsibilities

• Process Tuning & Optimization: Contribute across the process of Stack Forging, including laser cutting, metal-metal bonding, surface characterization/preparation, complex part geometry design, data and computational analysis, and material property optimization in the support of existing customer projects
• Root Cause Analysis: When things don’t go as expected, you figure out why. You quickly dive deep into the issue, collect critical data, and determine the root cause.
• Hands-On Execution: Your workspace will extend beyond your desk to the Production floor, where you will provide the production team with insight and expertise to ensure high-quality throughput.
• NPI Implementation: Spearhead the integration of new solutions and processes into active customer projects, ensuring they are ready for delivery.
• Feedback Loop: Act as the voice of the production floor for the broader engineering organization, identify long-term process improvements and testing capabilities required for effective delivery.

Qualifications

• Education: A Bachelor’s degree in engineering with 5–7 years of professional experience, or a PhD with 3+ years of experience.
• Relevant Experience: Previous work experience with at least one of the following: laser cutting, metallurgy, or statistical data analysis.
• Manufacturing background: Experience with manufacturing methods such as casting, machining, sheet metal forming or brazing
• Hardtech Grit: A proven track record of "making it happen" in complex hardware environments; you have demonstrated resilience and a commitment to getting solutions out the door.
• Communication: Strong ability to articulate technical trade-offs and project status to both internal teams and external customers.
• Tooling: Familiar with CAD (preferably Onshape), and proficiency with Python for data analysis.

Preferred Skills

• Adaptability: Previous experience working in a fast-paced, high-growth environment.
• Mass-Production Experience: Previous experience in a mass-production or high-volume environment.

SALARY RANGE

$112,100 - $187,000 (Salary to be determined by the education, experience, knowledge, skills, and abilities of the applicant, internal equity, and alignment with market data.) This role offers a competitive Bonus plan that will take into account individual, group, and corporate performance. 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