Process Engineer, Paint

The Paint Process Engineer role focuses on maintaining and improving paint shop performance through process optimization, defect reduction, and rigorous adherence to safety and quality standards. This role is located on site in Normal, IL and will report to the Manager of Process Engineering within the Paint Department

• Process Optimization (Manual Decks): Analyze and optimize manual deck operations across the entire paint shop (prep, masking, sanding, tacking, spraying, and finesse/polishing) to eliminate technique variations and reduce bottlenecks.

• Automated Sealer Quality: Monitor the quality output of automated sealer cells, collaborating directly with maintenance, technicians, and external contractors to troubleshoot equipment issues and ensure consistent, high-quality sealer application.

• Defect Resolution: Perform root cause analysis (e.g., 8D, 5 Whys) on paint and sealer defects (dirt, runs, sags, orange peel, skips) to implement permanent corrective actions, reduce manual rework, and minimize material waste.

• Tooling Implementation: Evaluate, source, and integrate improved tooling and equipment (e.g., ergonomic sanders, optimized masking dispensers, upgraded spray guns) to reduce operator fatigue and improve finish quality across all manual zones.

• Process Confirmation: Develop, maintain, and audit Standard Operating Procedures (SOPs). Conduct Layered Process Audits (LPAs) to verify adherence to validated techniques, fluid flow rates, and flash times.

• 5S & Contamination Control: Drive rigorous 5S practices across all manual decks and mixing rooms to eliminate dust/dirt contamination, organize chemicals/abrasives, and optimize point-of-use material flow.

• Safety & Ergonomics: Partner with Environmental Health and Safety (EHS) to mitigate VOC exposure hazards, ensure proper management of combustible materials, and resolve physical ergonomic risks at manual workstations.

• Continuous Improvement: Lead cross-functional Kaizen events and execute cost-reduction projects specific to the paint shop environment.

• Education: Bachelor’s degree in Chemical, Manufacturing or Industrial Engineering

• Experience: 3+ years of engineering experience directly supporting a manufacturing paint shop, with exposure to both manual processes and automated application cells.

• Technical Skills:

  • Deep understanding of fluid and sealer applications, paint defect identification, and contamination control protocols.
  • Proficiency in Lean Manufacturing, 5S methodologies, and Kaizen facilitation.
  • Strong background in structured problem solving (8D, Ishikawa) and Statistical Process Control (SPC).
  • Experience conducting time studies, line balancing, and ergonomic risk assessments.

• Communication: Ability to write clear technical documentation and effectively train, audit, and collaborate with shop-floor paint technicians, maintenance teams, and external contractors.