Senior Reliability Engineer

We are a diverse, enthusiastic, and growing team of multidisciplined engineers committed to advancing our mission of delivering mission-critical environments where it really matters through functionality, performance, and reliability of HVACR products meet and exceed demanding uptime and performance targets for applications such as data centers, commercial buildings, and industrial facilities. We work across multiple development programs and often step outside our normal roles to support a fast-paced environment. About You and The Role You are a hands-on engineer, who partners directly with design, controls, testing, manufacturing, service, and supplier teams to deliver reliability by design for our chiller portfolio. You’ll focus on compressors (screw, centrifugal, scroll), heat exchangers, pumps, fans, VFDs (Variable Frequency Drives), power electronics, sensors/actuators, and control systems—and the interactions among them—to ensure products meet stringent reliability, availability, and maintainability goals over the entire lifecycle. You will apply DFMEA (Design Failure Modes & Effects Analysis), Accelerated testing, RCA (Root Cause Analysis)/8D (Problem solving), and statistical life data analysis to drive decisions. We are the knowledge holders for how to validate field driven use cases, define critical parameters, and guide Cross functional execution so proper scope and timely outcomes are achieved. What You'll Do ● Own and drive the reliability strategy across air-cooled and water-cooled chiller programs with clear goals for failure-rate reduction, B10 life, and warranty cost. ● Translate design intent into reliability plans (Design-for-Reliability, DVP&R - Design Verification Plan, and Results) ensuring coverage of likely failure modes under realistic environmental and load profiles (thermal cycling, vibration, electrical stress, fouling). ● Manage and report reliability status for all programs—dashboards, risk registers, and readiness for phase gates—leading data-driven decisions. ● Connect field failure modes with validation standards and plans; update strategies as new field learnings emerge. ● Review ○ Requirements and validation methods to ensure what’s written matches how it’s verified and validated. ○ Program test strategies to maximize coverage and reduce redundant testing. ○ Program readiness at key milestones (concept, design freeze, design validation, product validation, launch). ● Conduct Root Cause Analysis (RCA/8D) on chronic issues across disciplines (e.g., bearing wear, VFD trips, refrigerant leaks, corrosion) and implement systemic corrective actions. ● Standardize reliability practices (DFMEA, Accelerated testing) with principal engineers and align supplier qualifications to reliability needs Must have Requirements • Bachelor’s degree in electrical, Mechatronics, Mechanical, or related engineering discipline. • 7-10 years of experience in product development, test, or field reliability; • Understanding of FMEA, RCA, recreating failure modes, and statistical analysis (e.g., Weibull) • Experience in designing and executing accelerated testing, Reliability testing. • Failure analysis experience. ● Demonstrated aptitude for debugging and troubleshooting in lab and field environments; strong curiosity and systematic problem solving Preferred qualifications ● Certified Reliability Engineer (ASQ-CRE) or equivalent, and understands distributions, Life Stress models, Reliability allocations, Design of Experiments (DoE) ● Ability to analyze test/field data, generate reliability reports, and communicate findings to drive design and process improvements. • Familiarity with electronics & controls (sensors, HMIs, drives), electro-mechanical interactions, and manufacturing processes affecting reliability. PART 2 Day to Day (what a typical day or week looks like in this role) ● Review DFMEA, DVP&R, field data, and customer duty cycles for a new chiller platforms; identify knowledge gaps and key risk areas; propose targeted reliability tests. ● Create reliability test requests with clear purpose, hypotheses/predictions, and acceptance criteria; align labs on configurations, fixtures, and schedules. ● Lead cross-functional discussions (design, controls, manufacturing, supply chain, service) to confirm deliverables, test readiness, and maturity; align on phase-gate expectations. ● Coordinate with lab personnel to ensure samples, instrumentation, and test stands (water loops, ambient chambers, power cycling rigs, vibration tables) meet the plan; manage execution across multiple labs. ● Review lab reports for completeness and traceability to requirements; ensure failure evidence, stress profiles, and data quality are adequate for decisions. ● Facilitate RCA/8D on failures (e.g., compressor internals, electronics thermal stress, refrigerant circuit leaks) and define effective short- and long-term corrective actions. ● Summarize test conclusions; document risks and defects; drive systemic learning. Use DoE where needed to confirm cause–effect and optimize design margins. ● Assess platform cross-impact—identify other models/options sharing similar risk—and communicate proactively to stakeholders. ● Lead process improvements in verification & validation and reliability standard work (gate criteria, stress profiles, acceptance tests). ● Engage with quality and service teams to capture field use cases (BMS logs, alarms, ambient/wet-bulb trends), perform site investigations when needed, and translate learnings into tests. ● Maintain reliability dashboards (program status, risks, actions) and trackers; keep Test-to Fail / Test-to-Learn (TTF/TTL) metrics current and visible. Johnson Controls: Enhancing the Intelligence of Buildings Your buildings have a purpose. They are places for people to live or work. Facilities for learning or healing. Venues for entertainment and shopping. Sites for the specialized storage of tangible goods or mission-critical data. Your buildings have a huge variety of functions; they are central to your mission. This is where Johnson Controls comes in, helping drive the outcomes that matter most. Through a full range of systems and digital solutions, we make your buildings smarter. A smarter building is safer, more comfortable, more efficient, and, ultimately, more sustainable. Most important, smarter buildings let you focus more intensely on your unique mission. Better for your people. Better for your bottom line. Better for the planet. At Johnson Controls, we’ve been making buildings smarter since 1885, and our capabilities, depth of innovation experience, and global reach have been growing ever since. Today, we offer the world’s largest portfolio of building products, technologies, software, and services; we put that portfolio to work to transform the environments where people live, work, learn and play.