Staff Engineer, Advanced Process
Work Mode: Onsite
Location: Onsite - Kohler, WI
Opportunity
We are seeking a Staff Engineer to lead the research, development,
qualification, deployment and continuous improvement of coating and finish
processes for K&B products. You will serve as the technical authority and
collaborative partner for finish development and surface engineering for metals
(e.g., PVD, powder coating, liquid paint, plating, anodizing), driving product
performance, durability, aesthetics, manufacturability, sustainability, and
cost.
This role is both hands-on and influential: you’ll define finish
technology roadmaps, develop standards, mentor engineers, closely partner with
design, marketing, product engineering and operations to develop and deploy
innovative finish solutions and support improving existing finish process at
manufacturing sites globally.
Technical Leadership
& Strategy
- Own the finishes technology roadmap for metal
finishing, aligned to product requirements, brand aesthetics, durability
targets, and sustainability goals.
- Establish and maintain finish standards,
specifications, and Design for Manufacturing (DFM).
- Lead complex root cause analysis and corrective
actions for finish-related failures (manufacturing, cosmetic, functional,
field/warranty).
Metal Product
Finishes & Surface Engineering
- Define, develop, and qualify new finishes for
stainless steel, brass, zinc die cast, aluminum, and steel substrates.
- Lead technology selection and optimization for powder
& lacquer, PVD, electroplating (Ni/Cr), anodizing, e-coat, conversion
coatings, passivation, electropolishing, brushing/bead-blast textures, and
specialty decorative finishes.
- Establish the best practices (cleaning, etching,
plasma/corona, adhesion promoters, silanes) to meet adhesion, corrosion,
and cosmetic targets.
- Develop cosmetic acceptance criteria and corrosion
performance requirements (salt spray, cyclic corrosion) tied to end-use
environments.
- Contribute to IP generation and technical
publications where appropriate.
Testing, Validation
& Standards
- Design test plans to validate coating design and
interpret data.
- Lead finish performance testing and coating
quality evaluation methods: corrosion resistance, weathering/UV, chemical
resistance, and abrasion/wear adhesion.
- Lead analytical characterization for thin and
thick films; SEM/EDS, XPS, XRD, TED, profilometry, gloss/colorimetry,
hardness, coating thickness (XRF) for metals/finishes.
Manufacturing,
Quality & Supplier Excellence
- Lead process transfers, start-ups, and scale-ups
with clear CTQs, process windows, and control methodologies.
- Partner with Operations/Quality to improve
first-pass yield, reduce cosmetic defect DPPM, and stabilize processes
using SPC and layered process audits.
- Support supplier development and qualification
with new finishes to ensure product quality and cost targets are achieved.
- Translate performance, aesthetic, and durability
requirements into finish selections and specs for design and sourcing
teams.
Problem Solving, Project
Management & Mentorship
- Strong problem-solving skills & competencies: Six
Sigma, DOE, root cause analysis tools & methodologies.
- Strong and disciplined project management capabilities
to plan, execute & document projects, effectively communicate project
status with project teams and senior leadership.
- Mentor junior engineers and technicians; provide
training on materials science, finishing technologies, and problem-solving
methods.
Skills/Requirements
- BS in Materials Science, Chemical Engineering, Mechanical Engineering, or related field; MS/PhD preferred.
- 6+ years in metal finish and coating development & deployment for consumer products, appliances, automotive, aerospace, medical, or similar industries. Key technologies: powder & lacquer, PVD, plating and mechanical finishing.
- Hands-on experience designing and interpreting finish validation and failure analysis, coating characterization methods.
- Strong supplier engagement skills: audits, trials, troubleshooting, and capability building.
- Excellent communication skills and the ability to influence across industrial design, marketing, engineering, quality, operations, and sourcing.
Applicants must be authorized to work in the US without requiring sponsorship now or in the future.
We believe in supporting you from the moment you join us, which is why Kohler offers day 1 benefits. This means you’ll have access to your applicable benefit programs from your first day on the job, with no waiting period.
The salary range for this position is $101,350 - $156,150. The specific salary offered to a candidate may be influenced by a variety of factors including the candidate’s experience, their education, and the work location. In addition, this position is eligible for a performance bonus/variable incentive compensation.
Why Choose Kohler?
We empower each associate to #BecomeMoreAtKohler with a competitive total rewards package to support your health and wellbeing, access to career growth and development opportunities, a diverse and inclusive workplace, and a strong culture of innovation. With more than 30,000 bold leaders across the globe, we’re driving meaningful change in our mission to help people live gracious, healthy, and sustainable lives.
About Us
It is Kohler’s policy to recruit, hire, and promote qualified applicants without regard to race, creed, religion, age, sex, sexual orientation, gender identity or expression, marital status, national origin, disability or status as a protected veteran. If, as an individual with a disability, you need reasonable accommodation during the recruitment process, please contact kohlerjobs@kohler.com. Kohler Co. is an equal opportunity/affirmative action employer.
