Paint Process Engineer

Job Purpose

To ensure smooth operation, optimization, and continuous improvement of the paint shop manufacturing process — focusing on productivity, paint quality, process parameters, cost reduction, and line efficiency while ensuring adherence to safety, environmental, and quality standards.

Key Responsibilities

Paint Shop Process Management

• Monitor and control paint shop processes to ensure consistent painting quality and throughput.
• Manage Paint process zones: Sealer, Primer, Top coat (Solid, Base Coat, and Clear Coat), including Plastic painting process.
• Maintain & monitor process parameters (temperature, flow rate, pressure, humidity, air balance) as per standard operating conditions.
• Monitor and control paint consumption, booth and oven parameters. for best energy and cost efficiency.
• Coordinate with maintenance for timely resolution of equipment or automation issues impacting production.

Paint Quality & Process Control

• Ensure paint film meets DFT (Dry Film Thickness), gloss, orange peel, and appearance standards.
• Develop Quality assurance Process, control plans, SOP’s etc. to support production and ensure smooth running of the process
• Plan & Conduct quality checks / confirmation – on the line ( Paint thickness, adhesion, finish etc.) & coordinate Lab tests towards process validation according to Volvo standards
• Work with the Quality team to analyze paint defects (e.g., runs, dust, fish eyes, pinholes) and drive corrective actions.
• Conduct root cause analysis (RCA) and implement Poka-Yoke / Mistake-proofing for process-related defects.
• Collaborate with suppliers for paint quality and formulation consistency (e.g., Nippon, Kansai, BASF).

Process Optimization & Continuous Improvement

• Implement Kaizen, TPM, and Lean Manufacturing initiatives in the paint shop.
• Lead projects for cycle time reduction, paint utilization improvement, and energy savings.
• Ensure process optimization towards consistent quality and higher transfer efficiency.
• Participate in new model trials, paint trials, and process validation during product changeovers.
• Drive Six Sigma / DOE studies for paint process capability (Cp, Cpk).

New Model & Equipment Implementation

• Support new model introduction (NPI) in paint shop — fixture validation, robot path teaching, paint booth calibration, and layout modification.
• Coordinate with vendor teams (Dürr, ABB, Fanuc, Eisenmann, etc.) during commissioning of new lines or upgrades.
• Develop and validate Standard Operating Procedures (SOPs) and Process Control Plans (PCPs).
• Participate in PFMEA (Process Failure Mode & Effects Analysis) and layout improvement studies.

Automation & Control Systems

• Handle Siemens S7 / Allen Bradley PLCs and HMI/SCADA systems used in the paint process.
• Trouble shoot PLC/HMI/Supervisory systems & able to program the logic control systems
• Knowledge on communication protocols/Network – Ethernet, Profinet
• Monitor and fine-tune robotic control systems (ABB/Durr/Fanuc) for paint application consistency.
• Interface PLCs with SCADA systems for real-time process data monitoring and alarms.
• Implement automation improvements to enhance process stability and reduce manual intervention.

Project - Installation & Commissioning

• Validate Paint shop RFQ – Coordinate for Installation & Commissioning of automation systems in paint shop project
• Coordinate with vendors , Project , Safety & Maintenance team during project phase
• Ensure equipment installation, commissioning & prove out as per the standard in brown field project
• Provide feedback during engineering phase of the project to vendors and ensure necessary controls are in place for SQPDC of the process

Technical Skills & Knowledge

Qualifications & Experience

Education:

• B.E. / B.Tech in Mechanical, Chemical, Production, or Industrial Engineering.

Experience:

• 3–8 years in automobile paint shop process/manufacturing engineering.
• Exposure to robotic painting, PLC-controlled paint lines, and new model trials preferred. Experience in automotive paint shops desired