Sr. Quality Engineer
Confirmed on the employer's own hiring board on Oct 14, 2026. First seen by Alion on Oct 1, 2026. Johnson Controls scores A on the Alion truth index.
Senior Manufacturing Quality Engineer
Position Summary
We are seeking a Senior Manufacturing Quality Engineer with 8+ years of direct manufacturing experience in assembly and fabrication environments to lead quality performance improvements across manufacturing operations and customer-facing quality initiatives. The successful candidate will be a technical leader responsible for driving defect reduction, improving process capability, strengthening quality systems, and ensuring customer satisfaction through structured problem solving and data-driven decision making.
This role requires a strong background in manufacturing quality engineering, root cause analysis, PFMEA, CAPA, GD&T, MSA, SPC, and continuous improvement methodologies. The individual will serve as a key liaison between Operations, Engineering, Supply Chain, and Customers, ensuring robust quality processes are deployed and sustained across the organization.
The ideal candidate demonstrates competencies aligned with the ASQ Certified Quality Engineer (CQE) Body of Knowledge or similar, including quality systems, product and process control, statistical analysis, risk management, continuous improvement, and leadership of cross-functional quality initiatives.
Key Responsibilities:
- Monitor, maintain and improve key quality metrics/ dashboards including DPU, FPY, NCRs, warranty, commissioning, and customer complaints of responsible product or program line.
- Develop, implement, and maintain Control Plans by collaborating with cross-functional teams including Operations, Engineering, Manufacturing, and Quality to ensure process risks are identified, controlled, and continuously improved.
- Develop, maintain, and analyze key quality and manufacturing metrics, conducting weekly KPI reviews to identify trends, drive corrective actions, and support data-driven decision making.
- Lead customer and manufacturing quality improvement initiatives across assigned product lines in a production environment and drive containment, CAPA, and continuous improvement activities to closure.
- Lead the implementation of advanced quality engineering practices, reliability methodologies, and digital quality technologies to enhance manufacturing performance, strengthen process controls, improve product reliability, and support the organization's quality transformation initiatives.
- Lead PFMEA, Control Plan, and risk assessment activities for new product introductions and existing products.
- Work with suppliers and interested parties by following MRB standards and support receiving inspection activities.
- Lead supplier quality issue resolution activities, including containment, root cause analysis, corrective actions, and verification of effectiveness to ensure compliance with quality and delivery requirements.
- Support internal and external audits and ensure compliance with ISO 9001 and QMS requirements.
- Partner with Operations, Engineering, Supply Chain, and Customers to resolve quality issues and improve performance daily.
- Serve as the quality leader during customer reviews, escalations, and manufacturing improvement projects.
Technical Competencies
- Strong working knowledge of GD&T interpretation and application, Measurement System Analysis (MSA), Statistical Process Control (SPC), Process Failure Mode and Effects Analysis (PFMEA), Control Plan development and maintenance, Corrective and Preventive Action (CAPA), process validation, reliability engineering principles, and risk assessment methodologies.
- Proven ability to lead and facilitate structured problem-solving activities utilizing 8D, A3, 5-Why, 9S, and other root cause analysis techniques.
- Experienced in reliability analysis, product life-cycle performance assessment, failure investigation, accelerated testing methodologies, and reliability improvement initiatives.
- Proficient in ISO 9001 Quality Management Systems, quality auditing, statistical analysis, and continuous improvement tools, with hands-on experience using Minitab, Power BI, and other data analytics and visualization platforms.
- Advanced proficiency in Microsoft Excel, PowerPoint, and Word, with the ability to develop, maintain, analyze, and present quality performance metrics, dashboards, and business insights to support data-driven decision making.
- Experience supporting assembly and fabrication manufacturing processes through quality planning, risk mitigation, process control, operational excellence initiatives, and cross-functional quality leadership.
Qualifications
- Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Electrical Engineering, or a related technical discipline OR relevant experience.
- Strong knowledge of assembly and fabrication manufacturing processes.
- Demonstrated ability to lead cross-functional teams and influence without direct authority.
- Excellent communication, project management, and organizational skills.
- Ability to operate effectively in a fast-paced manufacturing environment.
- Experience
- Minimum 8 years of direct manufacturing experience in assembly and fabrication environments.
- Minimum 5 years of progressive quality engineering experience.
- Proven record of improving quality performance, reducing defects, and driving corrective actions.
- Experience supporting New Product Introduction (NPI), process improvements, PFMEA, and Control Plan deployment.
- Experience interfacing with customers and managing customer quality concerns.
- Preferred
- ASQ Certified Quality Engineer (CQE) or similar.
- Experience leading PFMEA, Control Plans, CAPA, SPC, and continuous improvement initiatives.
- Completion of advanced training in GD&T, MSA, SPC, PFMEA, and structured problem-solving methodologies.
HIRING SALARY RANGE: $80,000-$110,000 (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
Johnson Controls’ Canadian subsidiaries are committed to providing reasonable accommodation to applicants, candidates and employees with disabilities, in accordance with applicable human rights legislation, and in Ontario, in accordance with the Accessibility for Ontarians with Disabilities Act (“AODA”). When requested, accommodation will be provided throughout all stages of the recruitment and selection process. To request accommodation, please contact us. Any information you provide related to accommodation measures will be treated as confidential. A copy of Johnson Controls’ applicable AODA policies are available on our website at www.johnsoncontrols.comfor your reference, and can be made available in accessible formats upon request.