Sr. Engineer - Advanced Manufacturing Automation

Carrier • Charlotte, NC

2d

About The Position

About Carrier: Carrier, global leader in intelligent climate and energy solutions, is committed to creating innovations that bring comfort, safety and sustainability to life. Through cutting-edge advancements in climate solutions such as temperature control, air quality and transportation, we improve lives, empower critical industries and ensure the safe transport of food, life-saving medicines and more. Since inventing modern air conditioning in 1902, we lead with purpose: enhancing the lives we live and the world we share. We continue to lead because of our world-class, inclusive workforce that puts the customer at the center of everything we do. For more information, visit corporate.carrier.com or follow Carrier on social media at @Carrier. About This Role: As a Sr. Engineer - Advanced Manufacturing Automation, you will lead the full lifecycle of automation delivery—from design and commissioning to long-term sustainment. You’ll pair deep technical expertise in PLC, HMI, and safety systems with a sharp financial lens, using cost modeling and ROI analysis to prioritize high-impact projects. By bridging the gap between engineering and Finance, you will identify and validate "hard savings" while providing technical leadership to external integrators. A data-driven problem solver at heart, you will ensure all automated solutions are high-performing, cost-effective, and rooted in a rigorous safety-first culture.

Requirements

• Bachelor’s degree
• 10+ years of experience delivering manufacturing automation in production environments
• 8+ years of experience building business cases and delivering verified savings (labor, scrap, uptime, FPY).
• 8+ years of experience in commissioning and sustaining automation systems in a live factory
• 5+ years of experience translating manufacturing problems into measurable improvement initiatives
• Ability to travel up to 25% of the time (international as needed)

Nice To Haves

• Bachelor’s degree in mechanical, Electrical, Mechatronics, Manufacturing, or Industrial Engineering
• Masters degree
• Experience with heat exchanger manufacturing (shell‑and‑tube and/or finned‑tube coils) and/or commercial HVAC chiller assembly.
• Experience with automated welding, brazing processes, and/or automated leak/pressure testing.
• Familiarity with MES/traceability, test data acquisition systems, and industrial networking.
• Lean/Six Sigma certification or equivalent CI leadership experience.
• Control Panel process and automation is a plus: Standardize and automate panel build processes where feasible: wire processing/labeling, poka‑yoke terminations, torque verification, functional test, PLC/VFD parameter loading, and traceability.

Responsibilities

• Automation Delivery Across Products & Processes (Technical Core)
• Heat Exchanger Automation
• Water‑cooled (shell‑and‑tube): tube bundle handling, tube‑to‑tube sheet joining (expansion and/or seal welding), shell/nozzle welding, and automated pressure/leak test systems.
• Air‑cooled (finned‑tube coils): tube insertion/expansion, header/manifold joining (brazing), automated coil leak/pressure testing, and coil handling/fixturing.
• Final Assembly Automation Implement flexible automation/assist solutions for heavy assembly, refrigerant charging systems, piping/brazing/welding support, sensor installation, control integration, and end‑of‑line (EOL) test automation and reporting.
• Controls, Test Systems & Manufacturing Digital Integration Own or support PLC/HMI/safety logic for manufacturing automation systems. Rockwell / Allen Bradley, Siemens are the typical PLC used. Drive reliability improvements through enhanced diagnostics, alarm rationalization, and fault recovery. Build/expand automated test capabilities (pressure/leak/functional) with recipe‑based execution and data capture. LabVIEW is typical test automation. Enable or improve traceability and test data capture through MES interfaces or structured data collection.
• Business Case, ROI & Hard Savings Ownership (What Makes This Role Different) Identify and quantify hard savings opportunities tied to automation: Labor reduction (direct touch time, overtime reduction, staffing flexibility) Scrap and rework reduction (weld defects, leaks, brazing defects, coil/piping rework) Downtime reduction / uptime gains (availability improvements and reduced lost units) Yield / FPY improvement (fewer retests, fewer escapes, reduced MRB burden) Warranty/field failure reduction where attributable to process improvements Energy and consumables reductions (where meaningful: gas, nitrogen, helium, tooling wear, etc.) Build clear automation investment cases (CapEx requests) including: Baseline losses and constraints Proposed solution options (buy/build/integrate) Payback period, NPV/IRR (when applicable), and sensitivity analysis Implementation costs (equipment, integration, downtime, training, spares) Prioritize project pipeline with focus on: Fast payback (e.g., ≤12–24 months) for many initiatives Scalable solutions that can replicate across lines/products Own benefits realization: Create a savings tracking plan with Finance Validate savings post‑implementation (30/60/90 days and quarterly) Put controls in place to sustain the savings (standard work, training, audits)
• Supplier/Integrator Leadership & Project Execution Lead vendors/integrators end‑to‑end: requirements, RFQ, technical evaluation, acceptance criteria, FAT/SAT, commissioning, ramp, and handoff. Define run‑at‑rate metrics and require demonstrable performance (cycle time, uptime, quality). Ensure maintainability: documentation, code management, spare parts, PM plans, and training packages.
• Quality, Safety & Compliance Embed safety and compliance into automation design and commissioning: Risk assessments, guarding, interlocks, LOTO readiness, safety validation Partner with New Product Introduction Engineers, Manufacturing Engineering and Quality to maintain: PFMEAs, control plans, reaction plans, capability checks for automated processes Drive defect reduction and escape prevention across welding/brazing/leak test operations .
• Continuous Improvement & Standardization Drive continuous improvement using data‑based root cause (8D/5‑Why/Fishbone) and Lean tools. Develop standards for automation: Preferred sensor types, safety architectures, HMI conventions, test data formats Reduce “tribal knowledge” dependence by building repeatable processes and troubleshooting playbooks

Benefits

• Employees are eligible for benefits, including:
• Health Care benefits: Medical, Dental, Vision; wellness incentives
• Retirement benefits
• Time Off and Leave: Paid vacation days, up to 15 days; paid sick days, up to 5 days; paid personal leave, up to 5 days; paid holidays, up to 13 days; birth and adoption leave; parental leave; family and medical leave; bereavement leave; jury duty; military leave; purchased vacation
• Disability: Short-term and long-term disability
• Life Insurance and Accidental Death and Dismemberment
• Tax-Advantaged Accounts: Health Savings Account; Healthcare Spending Account; Dependent Care Spending Account
• Tuition Assistance
• To learn more about our benefits offering, please click here: Work With Us | Carrier Corporate
• The specific benefits available to any employee may vary depending on state and local laws and eligibility factors, such as date of hire and the applicability of collective bargaining agreements.
• This position is entitled to short-term cash incentives, subject to plan requirements.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level