Job Description

Production Engineer (E-Coat & Powder Coat)

The Production Engineer is responsible for optimizing manufacturing processes, improving production efficiency, and ensuring the highest standards of quality, safety, and productivity within an automotive manufacturing environment. This role focuses on E-Coat (Electrocoating) and Powder Coating operations while supporting continuous improvement initiatives, equipment performance, process validation, and production readiness. The Production Engineer partners with Operations, Maintenance, Quality, and Engineering teams to reduce downtime, improve throughput, and ensure customer requirements are consistently achieved.

Essential Duties & Responsibilities

• Develop, optimize, and maintain production processes for E-Coat and Powder Coat operations.

• Monitor coating performance, process capability, and production efficiency while driving continuous improvement initiatives.

• Analyze production data to identify bottlenecks, reduce scrap, improve first-pass yield, and maximize Overall Equipment Effectiveness (OEE).

• Troubleshoot coating defects including adhesion failures, orange peel, runs, sags, pinholes, contamination, and curing issues.

• Optimize pretreatment systems, chemical concentrations, bath parameters, oven temperatures, and conveyor speeds.

• Support launch of new products by developing process parameters, work instructions, PFMEAs, control plans, and standard operating procedures.

• Collaborate with Maintenance to improve equipment reliability and minimize unplanned downtime.

• Lead Root Cause Analysis (RCA) using 5 Why, Fishbone, and 8D methodologies.

• Support APQP, PPAP, and customer launch activities for new automotive programs.

• Drive Lean Manufacturing initiatives including Kaizen events, 5S, waste reduction, and cycle time improvements.

• Ensure compliance with IATF 16949, ISO 9001, environmental regulations, and customer-specific requirements.

• Monitor and improve KPIs including productivity, scrap, first-pass yield, OEE, downtime, and labor efficiency.

• Evaluate and implement new coating technologies, automation improvements, and process enhancements.

Required Qualifications

• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Chemical Engineering, or related field. Will consider experience in lieu of a degree.

• 3+ years of Production Engineering experience within an automotive manufacturing environment.

• Hands-on experience with E-Coat and Powder Coat manufacturing processes.

• Strong understanding of pretreatment systems, phosphate processes, DI water systems, and coating chemistry.

• Experience optimizing curing ovens, conveyor systems, and automated paint lines.

• Knowledge of Lean Manufacturing, Six Sigma, and Continuous Improvement methodologies.

• Experience with Root Cause Analysis, PFMEA, Control Plans, APQP, and PPAP.

• Proficiency with Microsoft Office and manufacturing ERP/MES systems.

Preferred Qualifications

• Experience with robotic paint application systems (Fanuc, ABB, or Yaskawa).

• Knowledge of PLC-controlled automated manufacturing systems.

• Experience with conveyor automation and material handling systems.

• Six Sigma Green Belt or Black Belt certification.

• Lean Manufacturing certification.

• Experience supporting automotive OEMs and Tier 1 suppliers.

Technical Skills

• E-Coat (Electrocoating) Process Optimization

• Powder Coat Systems

• Pretreatment & Phosphate Systems

• Paint Chemistry

• Cure Oven Optimization

• Automated Paint Lines

• Robotic Paint Systems