Sr. Engineer - Advanced Manufacturing Automation

Carrier Corporation • Charlotte, NC

7d

About The Position

About Carrier Carrier Global Corporation, 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 safe transport of food, lifesaving 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 on Carrier 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)
• 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

• 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 leave; military leave; purchased vacation
• Disability : Short-term and long-term disability
• Life Insurance and Accidental Death and Dismemberment
• Tax-Advantaged Accounts: Health Savings Account; Health Care Spending Account; Dependent Care Spending Account
• Tuition Assistance

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level
• Number of Employees: 5,001-10,000 employees