Thin Film Coating Process Engineer Jobs in Michigan

Albar Industries is seeking a highly motivated and technically skilled Paint Process Engineer to provide leadership and support for automotive paint operations involving robotic painting of metal, SMC, and injection molded plastic interior and exterior components. This position combines responsibilities in paint process engineering, robotic automation, paint laboratory testing, quality assurance, process optimization, and continuous improvement.

The successful candidate will be responsible for developing, launching, maintaining, and improving paint systems and coating processes while ensuring compliance with customer, OEM, quality, environmental, and safety requirements. This role works closely with production, quality, engineering, maintenance, suppliers, and customers to drive operational excellence and deliver world-class painted products.

Essential Duties and Responsibilities

Paint Process Engineering & Product Launch Support

• Lead all paint-related activities associated with new product launches.
• Develop and optimize robotic paint programs.
• Maximize paint transfer efficiency, production throughput, and coating quality while minimizing waste and cycle time.
• Develop paint application processes for 1K and 2K and solvent-borne coating systems.
• Work with paint suppliers to optimize coating performance and ensure compliance with customer specifications.
• Support coating development including dry film thickness, gloss, color, adhesion, and appearance requirements.
• Develop and validate process parameters for paint application, curing, and surface preparation operations.
• Evaluate and improve paint rack designs to ensure proper coverage, efficient loading and unloading, operator safety, and ergonomic performance.
• Collaborate with packaging suppliers to develop work-in-process packaging solutions that protect product quality.

Paint Laboratory & Quality Activities

• Perform and oversee laboratory testing of coatings and painted products.
• Conduct wet film thickness (WFT) and dry film thickness (DFT) measurements.
• Perform color evaluations using visual methods and color measurement equipment.
• Analyze gloss, appearance, and color variation against customer and OEM standards.
• Understand and evaluate coating defects including porosity, splay, flash, orange peel, adhesion failures, inclusions, dirt, and other appearance concerns.
• Maintain knowledge of paint testing procedures, specifications, and industry standards.
• Ensure compliance with OEM performance testing and appearance requirements.
• Verify incoming paint materials and critical coating properties in conjunction with Quality personnel.
• Conduct batch checks and help resolve coating material discrepancies.

Production Support

• Provide daily technical support for paint operations, spray booths, robots, and application equipment.
• Monitor paint line performance and process settings.
• Review paint processes and document deviations, trials, process changes, or out-of-control conditions.
• Counsel paint operations personnel regarding coating selection, spray patterns, application techniques, and process optimization.
• Troubleshoot paint process and equipment issues and implement corrective actions in a timely manner.
• Develop and update standardized work instructions and operating procedures.
• Conduct audits to verify process compliance and adherence to standardized work practices.

Continuous Improvement

• Lead root cause problem-solving activities utilizing 5-Why analysis and other structured methods.
• Support scrap reduction, defect reduction, and process optimization projects.
• Participate in lean manufacturing and operational excellence initiatives.
• Analyze paint consumption, transfer efficiency, labor utilization, and cycle times.
• Identify opportunities to improve productivity, quality, and cost performance.
• Document lessons learned and share best practices across the organization.
• Investigate automation opportunities to improve process consistency, reliability, and efficiency.
• Support PLC-controlled process improvements and manufacturing automation initiatives.

Equipment & Process Development

• Assist with the design, layout, and optimization of paint spray booths and application systems.
• Support evaluation and implementation of curing technologies including infrared (IR), convection, and UV systems.
• Prepare proposals and justifications for capital equipment investments and cost-saving initiatives.
• Support implementation of new technologies and emerging coating systems.

Reporting & Documentation

• Enter, analyze, and interpret data using electronic and manual systems.
• Maintain coating specifications, mixing instructions, process documentation, and work instructions.
• Generate reports and presentations using Microsoft Office applications.
• Track multiple projects and prioritize work to meet deadlines and customer requirements.

Customer & Cross-Functional Support

• Ensure product testing meets all current customer specifications.
• Support manufacturing operations in producing quality products that satisfy customer requirements.
• Coordinate activities with Production, Quality, Engineering, Maintenance, Purchasing, and Suppliers.
• Review paint process findings and communicate recommendations to appropriate personnel.
• Promote collaboration and teamwork to achieve company objectives.

Required Qualifications

Education & Experience

• Bachelor's Degree in Engineering, Chemical Engineering, Manufacturing Engineering, Materials Science, or a related technical discipline; OR
• Minimum of two (2) years of experience in automotive manufacturing, industrial coatings, paint processing, paint laboratory operations, or a related field.

Required Knowledge & Skills

• Strong understanding of paint chemistry and coating technologies.
• Knowledge of automotive paint application processes.
• Ability to perform mathematical calculations and interpret graphs, charts, and technical data.
• Understanding of Statistical Process Control (SPC).
• Ability to analyze problems and make sound technical decisions.
• Strong project management, organization, and time management skills.
• Effective verbal and written communication skills.
• Proficiency in Microsoft Excel, Word, and PowerPoint.
• Ability to follow written and verbal instructions.
• Ability to work independently and as part of a team.

Preferred Qualifications

• Automotive Class A paint experience.
• Experience programming Fanuc paint robots.
• Knowledge of 1K and 2K coatings, including basecoat and clearcoat systems.
• Experience with automatic spray application equipment.
• Knowledge of PD2K Fluid Delivery Systems.
• Knowledge of lean manufacturing principles.
• Experience with PLC programming.
• Familiarity with paint booth design and layout.
• Knowledge of thermal curing, IR curing, convection curing, and UV curing technologies.
• Experience with CO₂ cleaning, and other surface preparation methods.
• Experience working directly with paint suppliers to optimize coating performance and resolve quality issues.
• Ability to pass a Munsell Color Vision Test.

Safety, Environmental & Quality Responsibilities

• Understand and support the company's Quality and Environmental Management Systems.
• Follow all company policies, procedures, and safety requirements.
• Maintain a clean, organized, and professional work environment.
• Support environmental compliance requirements related to coatings, emissions, and hazardous materials.
• Utilize appropriate personal protective equipment (PPE).
• Support continuous improvement of safety, quality, delivery, and cost performance.

Work Environment

• Automotive manufacturing environment.
• Exposure to automated equipment, robotics, and production machinery.
• Exposure to paint and solvent vapors controlled through approved respiratory protection.
• Elevated temperatures and humidity during seasonal conditions.
• Interaction with laboratory and production environments.

Success in This Role

The ideal candidate combines expertise in robotic paint automation, paint chemistry, laboratory testing, quality systems, and manufacturing process improvement with a passion for operational excellence. This individual serves as the technical leader for paint operations while ensuring products consistently meet customer requirements for appearance, performance, quality, safety, and cost.