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Job Description
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 tube/metal fabrication processes (e.g., cutting, forming, coiling, insulating). 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/fabrication issues such as adhesion failures, surface defects, quality issues, dimensional variation, etc.
Coating Operations Support
- Manage coating system performance (chemistry control, line speed, cure cycles, 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/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