Advanced Manufacturing Staff Engineer
Carrier Global · Santa Catarina
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 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 Carrier or follow Carrier on social media at @Carrier.
About the role
As an Advanced Manufacturing Staff Engineer, you will play a key role in developing and implementing advanced manufacturing and mechanical automation solutions across HVAC manufacturing operations.
This position combines mechanical automation, equipment and fixture design, industrialization, project execution, and financial ownership. You will identify manufacturing opportunities, translate them into scalable technical solutions, build strong CAPEX business cases, and ensure that projects deliver measurable improvements in labor efficiency, scrap, downtime, yield, quality, and overall operational performance.
You will work cross-functionally with Manufacturing, Product Engineering, Quality, EHS, Finance, Operations, and external suppliers to take automation projects from concept and design through commissioning, production launch, and sustained performance.
Key Responsibilities
As an Advanced Manufacturing Staff Engineer, you'll be responsible for:
- Lead the development and implementation of mechanical automation solutions for HVAC products and manufacturing processes, including water-cooled shell-and-tube heat exchangers, air-cooled finned-tube coils, and final assembly operations.
- Develop automation solutions for tube handling, tube-to-tubesheet joining, shell and nozzle welding, brazing, coil handling and fixturing, refrigerant charging, sensor installation, and automated pressure and leak testing.
- Develop flexible automation and manufacturing assistance solutions for heavy assembly processes, piping, brazing, welding, controls integration, and end-of-line testing and reporting.
- Lead the conceptualization and integration of subassembly systems, translating product, process, ergonomics, quality, safety, and capacity requirements into robust and scalable mechanical solutions.
- Develop and validate 3D mechanical designs and 2D drawings for workstations, fixtures, tooling, clamping devices, assembly aids, and material handling systems.
- Apply GD&T, tolerance analysis, DFM/DFA principles, material selection, datums, locating strategies, ergonomics, maintainability, safety, and poka-yoke principles to manufacturing equipment and tooling.
- Coordinate the fabrication, assembly, installation, debugging, and validation of fixtures and subassembly equipment in collaboration with suppliers, Product Engineering, Quality, EHS, Manufacturing, and Operations.
- Lead industrialization and production release activities, including dimensional validation, capability studies, run-at-rate, technical documentation, work instructions, training, change control, and handoff to operations.
- Identify and quantify hard-savings opportunities through automation, including direct labor reduction, overtime reduction, scrap and rework reduction, downtime improvements, increased availability, improvements in yield and FPY, warranty reduction, and optimization of energy and consumables.
- Develop CAPEX business cases that clearly define baseline losses and constraints, proposed technical solutions, implementation costs, payback period, and, when applicable, NPV, IRR, and sensitivity analysis.
- Prioritize automation projects based on business impact, scalability, technical feasibility, and ROI, with a focus on solutions that can be replicated across manufacturing lines and products.
- Partner with Finance to establish savings tracking plans and validate realized benefits following implementation, including 30/60/90-day and quarterly reviews.
- Implement controls to sustain project benefits through standard work, training, audits, and operational follow-up.
- Lead suppliers and system integrators throughout the complete project lifecycle, including requirements definition, RFQs, technical evaluations, acceptance criteria, FAT/SAT, commissioning, ramp-up, and final handoff.
- Define run-at-rate requirements and verify demonstrated performance against cycle time, availability, and quality expectations.
- Ensure equipment maintainability through appropriate documentation, code management, spare parts strategy, preventive maintenance planning, and training.
- Integrate safety and compliance requirements into automation design and commissioning, including risk assessments, guarding, interlocks, LOTO readiness, and safety validation.
- Collaborate with New Product Introduction, Manufacturing Engineering, and Quality teams to maintain PFMEAs, control plans, reaction plans, and capability verification for automated manufacturing processes.
- Drive defect reduction and escape prevention across welding, brazing, and leak-testing operations.
- Lead continuous improvement activities using data-driven root cause analysis methodologies such as 8D, 5 Whys, Ishikawa, and Lean tools.
- Develop and promote manufacturing automation standards, including preferred sensor types, safety architectures, HMI conventions, and test-data formats.
- Reduce dependency on tribal knowledge by developing repeatable processes, technical standards, documentation, and troubleshooting guides.
Requirements
We are looking for people who are analytical, technically driven, results-oriented, and passionate about manufacturing automation and continuous improvement. If this is you, get in touch.
As a minimum you must have:
- Bachelor's degree in Engineering or a related technical field.
- 5+ years of experience implementing manufacturing automation solutions in production environments.
- 3+ years of experience developing business cases and delivering verified hard savings related to labor, scrap, availability, productivity, or FPY.
- 4+ years of experience commissioning and sustaining automation systems within an operating manufacturing facility.
- Demonstrated ability to translate manufacturing challenges into measurable technical improvement initiatives.
- Experience with AutoCAD.
- Experience in mechanical conceptualization and integration of subassembly systems, from design through industrialization and production support.
- Experience with 3D CAD and development of 2D manufacturing drawings for workstations, fixtures, tooling, and assembly aids.
- Knowledge of GD&T, tolerance analysis, material selection, DFM/DFA, ergonomics, safety, maintainability, and poka-yoke.
- Experience with industrialization, technical documentation, run-at-rate, change control, and production process release.
- Experience developing cost models and prioritizing projects based on ROI.
- Experience providing technical leadership to suppliers, tooling manufacturers, workshops, or system integrators.
- Strong data-driven problem-solving skills and commitment to safety, quality, and compliance.
Although not necessary, it would be nice if you have:
- Bachelor's degree in Mechanical, Electrical, Mechatronics, Manufacturing, or Industrial Engineering. Master's degree is a plus.
- Experience in heat exchanger manufacturing, including shell-and-tube and/or finned-tube coils, or commercial HVAC chiller assembly.
- Experience with automated welding, brazing processes, and/or automated leak and pressure testing.
- Familiarity with MES, traceability systems, test-data acquisition systems, and industrial networks.
- Lean or Six Sigma certification, or equivalent experience leading continuous improvement initiatives.
- Experience with control panel manufacturing processes and automation, including wire processing and labeling, poka-yoke terminations, torque verification, functional testing, PLC/VFD parameter loading, and traceability.
Benefits
We offer a competitive total rewards package that may include other benefits and well-being programs. Offerings vary by role and location and are designed to support employees’ health, security, and success.
If you require a reasonable accommodation to complete the application process, participate in an interview, or otherwise engage in the hiring process, please contact us at Carrier.Recruiting@carrier.com. We will make every effort to meet your needs in accordance with applicable laws.
Carrier is An Equal Opportunity/Affirmative Action Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability or veteran status, age or any other federally protected class.
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