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.
CUSTOM.PAY.TRANSPARENCY
Why Choose Kohler?
We empower each associate to 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 . Kohler Co. is an equal opportunity/affirmative action employer.
