Kohler Co. · 13 hours ago
Staff Engineer, Advanced Process
Kohler, WI
Full-time
Onsite
Senior Level, Lead/Staff
$101K/yr - $156K/yr
6+ years expKohler is a company focused on innovation and sustainability, and they are seeking a Staff Engineer to lead the research and development of coating and finish processes for their products. This role involves defining technology roadmaps, mentoring engineers, and collaborating with various teams to improve and innovate finish solutions.
Consumer Goods
No H1B
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
Qualification
Required
BS in Materials Science, Chemical Engineering, Mechanical Engineering, or related field
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
Preferred
MS/PhD in Materials Science, Chemical Engineering, Mechanical Engineering, or related field
Benefits
Day 1 benefits
Performance bonus/variable incentive compensation
Competitive total rewards package
Access to career growth and development opportunities
A diverse and inclusive workplace
A strong culture of innovation
Company
Kohler Co.
We’re a community of creators. Status quo busters. Difference makers.
10001+ employees
Funding
Current Stage
Late StageLeadership Team
David Kohler
Chair & Chief Executive Officer
.Davor Grgic
Consultant — Retired CIO & VP - Sustainability
Recent News
2025-08-07
Google Patent
2025-05-07
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