Position Summary
The Coating & Fabrication Process Engineer is responsible for developing, optimizing, and sustaining manufacturing processes related to metal coating operations (e.g., galvanizing, liquid paint, plating, conversion coatings, etc.) and tubemetal fabrication processes (e.g., cutting, forming, coiling, insulating, etc.). This role drives improvements in quality, yield, throughput, cost, and safety while supporting production teams and meeting customer requirements.
Key Responsibilities
Process Engineering & Optimization
Improve coating and fabrication processes to reduce defects, scrap, and rework. Establish and maintain process parameters, work instructions, and control plans. Lead process trials, DOE pilot runs, to validate improvements and new materials. Troubleshoot coating and fabrication issues, such as adhesion failures, surface defects, quality issues, and dimensional variation.
Coating Operations Support
Manage coating system performance, chemistry control, line speed, cure cycles, and surface prep. Monitor coating thickness, uniformity, adhesion, cure performance, and appearance standards. Coordinate with suppliers on coating materials, pretreatment chemicals, and performance testing. Support compliance with customer specs and coating standards (ASTM, ISO, internal specs).
Fabrication Operations Support
Improve fabrication processes, including forming, cutting, and finishing operations. Develop tooling, fixtures, and error-proofing methods (poka-yoke). Support machine capability studies and reduce downtime through process stability improvements. Improve cycle time and line balancing for throughput gains.
Quality & Continuous Improvement
Lead root cause investigations using 5-Why, fishbone, SPC, PFMEA, and corrective actions. Partner with Quality to resolve customer complaints and internal nonconformances. Drive lean manufacturing initiatives, waste reduction, standard work, visual controls. Maintain key manufacturing KPIs (OEE, scrap rate, FPY, rework, downtime).
Documentation & Standards
Develop and maintain SOPs, process maps, control plans, and PFMEAs. Support training of operators and technicians on best practices and process standards. Ensure proper gauge, test method usage, thickness, adhesion, salt spray, crosshatch, etc.
Equipment & Capital Projects
Support equipment upgrades, automation, and preventive maintenance improvements. Specify new process equipment, coating booths, ovens, curing, cleaning systems, welders, presses, etc. Lead or support capital projects from concept through commissioning and startup.
Safety & Environmental Compliance
Promote safe work practices and support EHS initiatives. Ensure coating processes comply with air, chemical handling, and waste management standards. Participate in risk assessments and implement corrective actions for hazards.