Staff Engineer, Advanced Process

Kohler Co. • Kohler, WI

1d • Onsite

About The Position

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.

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.

Responsibilities

• 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).
• 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.
• 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.
• 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.
• 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.

Benefits

• 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.
• In addition, this position is eligible for a performance bonus/variable incentive compensation.
• 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.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level