Staff Engineer, Advanced Process

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.

Work Mode:
Onsite

Location:

Onsite - Kohler, WI

• 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.

• 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.

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…