Sr. Staff Process Engineer

Sr. Staff Process Engineer Kohler Reynosa Plant Location: Reynosa, Tamps. / Onsite Position Summary The Senior Staff Process Engineer is the technical authority responsible for the development, optimization, standardization, and continuous improvement of Hydraulic Deep Draw Pressing, Process Washing, and Heat Treatment operations. This role provides advanced engineering leadership in stainless steel manufacturing processes, tooling systems, metallurgy, furnace atmosphere controls, industrial cleaning processes, and new product introduction activities. The position partners closely with Manufacturing, Product Engineering, Tooling, Maintenance, Quality, Supply Chain, and Operations leadership to improve safety, quality, productivity, reliability, and cost performance while supporting strategic manufacturing initiatives and capital projects. Essential Duties and Responsibilities Heat Treatment Annealing Operations

• Provide technical leadership for annealing, bright annealing, and heat treatment processes for stainless steel products.
• Develop, implement, and maintain process controls for furnace operations and atmosphere management systems.
• Apply metallurgical principles to optimize material properties, grain structure, mechanical performance, corrosion resistance, and cosmetic requirements.
• Support and optimize hydrogen generation systems, including ammonia dissociation and other hydrogen sources.
• Manage nitrogen generation systems, liquid nitrogen storage, distribution, consumption, and purity requirements.
• Establish and maintain standards for heat treatment atmosphere measurement, monitoring, and analysis.
• Develop and maintain dew point control programs, measurement techniques, and process specifications.
• Lead troubleshooting and root cause analysis of heat treatment defects, discoloration, oxidation, contamination, and process variation.
• Conduct engineering research and benchmarking activities to improve quality, throughput, energy efficiency, and operating costs. Process Washing Operations
• Develop and maintain process controls for industrial washing operations utilizing caustic cleaners, alkaline soaps, detergents, and surfactants.
• Establish operating standards for wash chemistry concentration, temperature, rinse quality, and contamination control.
• Support process water treatment systems including: o Water softeners o Reverse osmosis systems o Process water monitoring systems o Water quality improvement initiatives
• Utilize chemistry-based analytical methods, including titration techniques, to verify active cleaner concentrations and wash chemistry performance.
• Establish cleanliness verification methods and standards including: o Surface energy testing o Wetting analysis o Dyne measurements o Water break testing o Other cleanliness measurement methods
• Lead projects focused on water conservation, chemical optimization, waste reduction, and operating cost improvements.
• Conduct engineering research to identify improved washing technologies and process enhancements. Hydraulic Pressing and Tooling Operations
• Serve as the technical expert for hydraulic press operations used in stainless steel deep drawing, forming, trimming, piercing, and cutting applications.
• Develop and optimize deep draw manufacturing processes to improve product quality, process capability, and operational efficiency.
• Evaluate tooling designs and recommend improvements to maximize tool life, part consistency, and throughput.
• Interpret engineering drawings, tooling blueprints, specifications, and manufacturing standards.
• Apply Geometric Dimensioning and Tolerancing (GD T) principles during process development, troubleshooting, and capability analysis.
• Support tooling material selection, coatings, heat treatment requirements, and wear-resistant technologies.
• Demonstrate working knowledge of tribology principles including friction, wear, lubrication, and material interactions.
• Develop and optimize lubrication systems, drawing compounds, process films, and associated manufacturing controls.
• Provide technical guidance regarding process waste streams, environmental compliance requirements, and process discharge management.
• Lead troubleshooting activities related to forming defects such as tearing, wrinkling, galling, thinning, springback, and dimensional variation.
• Support new product development through Design for Manufacturability (DFM) reviews and manufacturing feasibility assessments.
• Recommend product and process improvements to improve manufacturability, quality, and cost. General Process Engineering Responsibilities
• Develop and maintain Standard Work documentation.
• Create, revise, and implement Standard Operating Procedures (SOPs).
• Develop labor standards, manufacturing work instructions, and operator training materials.
• Perform ergonomic assessments and implement process improvements to reduce risk and improve productivity.
• Conduct capacity analysis, line balancing studies, and manufacturing constraint evaluations.
• Lead continuous improvement initiatives utilizing Lean Manufacturing principles.
• Research, specify, and justify new manufacturing equipment and technologies.
• Develop and manage capital project proposals and implementation activities.
• Lead equipment installation, startup, validation, and process qualification activities.
• Partner with Maintenance to develop and improve preventive maintenance strategies for existing and new equipment.
• Utilize data analysis and statistical methods to improve process capability and operational performance.
• Lead structured root cause investigations and corrective action implementation.
• Mentor and provide technical guidance to engineers, technicians, supervisors, and production personnel