{"id":2975681,"url":"https://alion.io/job/kohler-sr-staff-process-engineer","title":"Sr. Staff Process Engineer","company":{"id":1756392,"name":"Kohler","domain":"kohler.com","url":"https://alion.io/company/kohler","size_band":"1001-5000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Cornerstone","truth_index":{"grade":"B","score":78,"open_postings":24,"ghost_share":0,"stale_share":0.875,"repost_share":0,"time_to_fill_p50_days":39,"computed_at":"2026-10-24T06:02:35Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"staff","employment_type":null,"work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Reynosa, Mexico"],"countries":["MX"],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":{"min_usd":45000,"max_usd":104000,"period":"year","method":"global_role_cell_scaled_by_country","sample_n":1625},"experience_years_min":null,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[],"status":"live","first_seen_at":"2026-10-20T12:00:00Z","employer_posted_date":"2026-10-21","last_verified_at":"2026-10-24T13:22:10Z","board_verified":true,"closed_at":null,"days_open":4,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":4},"description":"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\nProvide technical leadership for annealing, bright annealing, and heat treatment processes for stainless steel products.\nDevelop, implement, and maintain process controls for furnace operations and atmosphere management systems.\nApply metallurgical principles to optimize material properties, grain structure, mechanical performance, corrosion resistance, and cosmetic requirements.\nSupport and optimize hydrogen generation systems, including ammonia dissociation and other hydrogen sources.\nManage nitrogen generation systems, liquid nitrogen storage, distribution, consumption, and purity requirements.\nEstablish and maintain standards for heat treatment atmosphere measurement, monitoring, and analysis.\nDevelop and maintain dew point control programs, measurement techniques, and process specifications.\nLead troubleshooting and root cause analysis of heat treatment defects, discoloration, oxidation, contamination, and process variation.\nConduct engineering research and benchmarking activities to improve quality, throughput, energy efficiency, and operating costs. Process Washing Operations\nDevelop and maintain process controls for industrial washing operations utilizing caustic cleaners, alkaline soaps, detergents, and surfactants.\nEstablish operating standards for wash chemistry concentration, temperature, rinse quality, and contamination control.\nSupport process water treatment systems including: o Water softeners o Reverse osmosis systems o Process water monitoring systems o Water quality improvement initiatives\nUtilize chemistry-based analytical methods, including titration techniques, to verify active cleaner concentrations and wash chemistry performance.\nEstablish 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\nLead projects focused on water conservation, chemical optimization, waste reduction, and operating cost improvements.\nConduct engineering research to identify improved washing technologies and process enhancements. Hydraulic Pressing and Tooling Operations\nServe as the technical expert for hydraulic press operations used in stainless steel deep drawing, forming, trimming, piercing, and cutting applications.\nDevelop and optimize deep draw manufacturing processes to improve product quality, process capability, and operational efficiency.\nEvaluate tooling designs and recommend improvements to maximize tool life, part consistency, and throughput.\nInterpret engineering drawings, tooling blueprints, specifications, and manufacturing standards.\nApply Geometric Dimensioning and Tolerancing (GD T) principles during process development, troubleshooting, and capability analysis.\nSupport tooling material selection, coatings, heat treatment requirements, and wear-resistant technologies.\nDemonstrate working knowledge of tribology principles including friction, wear, lubrication, and material interactions.\nDevelop and optimize lubrication systems, drawing compounds, process films, and associated manufacturing controls.\nProvide technical guidance regarding process waste streams, environmental compliance requirements, and process discharge management.\nLead troubleshooting activities related to forming defects such as tearing, wrinkling, galling, thinning, springback, and dimensional variation.\nSupport new product development through Design for Manufacturability (DFM) reviews and manufacturing feasibility assessments.\nRecommend product and process improvements to improve manufacturability, quality, and cost. General Process Engineering Responsibilities\nDevelop and maintain Standard Work documentation.\nCreate, revise, and implement Standard Operating Procedures (SOPs).\nDevelop labor standards, manufacturing work instructions, and operator training materials.\nPerform ergonomic assessments and implement process improvements to reduce risk and improve productivity.\nConduct capacity analysis, line balancing studies, and manufacturing constraint evaluations.\nLead continuous improvement initiatives utilizing Lean Manufacturing principles.\nResearch, specify, and justify new manufacturing equipment and technologies.\nDevelop and manage capital project proposals and implementation activities.\nLead equipment installation, startup, validation, and process qualification activities.\nPartner with Maintenance to develop and improve preventive maintenance strategies for existing and new equipment.\nUtilize data analysis and statistical methods to improve process capability and operational performance.\nLead structured root cause investigations and corrective action implementation.\nMentor and provide technical guidance to engineers, technicians, supervisors, and production personnel","description_format":"text","description_chars":5697,"description_truncated":false,"requirements":{"experience_years_min":null,"management_years_min":null,"team_size_min":null,"manages_managers":false,"education":null,"security_clearance":false,"languages":[]},"benefits":[],"hiring_locations":[],"hiring_excludes":[],"relocation_offered":false,"industries":["Hotels & Resorts","Kitchens, Bathrooms & Home Improvement"],"lifecycle":[{"event":"open","at":"2026-10-21T04:29:37Z"}],"visa":[],"liveness":{"score":63,"band":"ok","label":"Likely open","p_open":1,"p_active":0.632,"p_room":1,"age_days":3,"expected_fill_days":39,"reasons":["conf:1","stale_co","velocity","win:early","comp:brand"],"computed_at":"2026-10-24T06:02:35Z"},"pay":null,"html_url":"https://alion.io/job/kohler-sr-staff-process-engineer","json_url":"https://alion.io/job/kohler-sr-staff-process-engineer.json","meta":{"generated_at":"2026-10-24T14:30:06Z","cache_seconds":300,"methodology":"https://alion.io/methodology","terms":"https://alion.io/terms","contact":"https://alion.io/contact","api":"https://alion.io/developers","about":"Alion is a live layer of people, companies and AI agents: who they are, whether they are real and active right now, what they do and how to work with them, readable by people and by agents and paid per call.","catalog":"https://alion.io/catalog.json","usage":{"tier":"crawler_verified","counted_by":"address","units_charged":1,"used_today":20669,"day_limit":null,"remaining_today":null,"minute_limit":300,"resets_at":"2026-10-25T00:00:00Z"}},"offers":[{"id":"company.slices","title":"One company in depth, by slice","status":"live","price":{"credits":0.02,"usd":0.002,"plus_per_slice":{"credits":0.05,"usd":0.005}},"unit":"per company, plus each slice with data","note":"the employer in depth","call":{"mcp_tool":"get_company","arguments":{"id":1756392},"rest":"https://alion.io/mcp/rest/get_company?id=1756392"},"human":"https://alion.io/catalog?offer=company.slices&for=job%2Fkohler-sr-staff-process-engineer"},{"id":"market.stats","title":"A market slice: pay, demand and time to fill","status":"live","price":{"credits":1,"usd":0.1},"unit":"per slice","note":"pay, demand and time to fill for this role and place","call":{"mcp_tool":"market_stats"},"human":"https://alion.io/catalog?offer=market.stats&for=job%2Fkohler-sr-staff-process-engineer"},{"id":"job.search","title":"Open jobs by role, technology, place, pay and visa","status":"live","price":{"credits":0.02,"usd":0.002},"unit":"per posting in a list","note":"similar open postings","call":{"mcp_tool":"search_jobs"},"human":"https://alion.io/catalog?offer=job.search&for=job%2Fkohler-sr-staff-process-engineer"},{"id":"company.verify","title":"Is this company real and active right now","status":"pilot","price":null,"unit":"per company","request":{"url":"https://alion.io/catalog/request","method":"POST","body":"{\"offer\": \"company.verify\", \"for\": \"job/kohler-sr-staff-process-engineer\", \"note\": \"what you need it for\"}"},"human":"https://alion.io/catalog?offer=company.verify&for=job%2Fkohler-sr-staff-process-engineer"}]}