Charl Coetser
Villa Rica,GA
Summary
Dedicated Senior Process Engineer with over ten years of experience in the Automotive industry, mainly for a Tier 1 OEM supplier of painted exterior components. Highly skilled in continuous improvement, with a major focus on sustainability and long term process reliability. Proven leader of multiple teams, emphasizing the impact that each team member can make on the overall success of the business. Thrives in a dynamic work environment in an industry where technology is evolving at a rate that demands constant innovation to prepare for tomorrow's challenges. Experienced in launching product lines from varying automotive OEM customers with distinctly different cultural backgrounds, requirements, quality expectations, and technologies.
Overview
11
11
years of professional experience
Work History
Sr. Paint Process Engineer
Decostar Industries - Magna International
01.2023 - Current
- Led team of 30 operators, technicians, and supervisors, overseeing daily production activities and drive for continuous improvement.
- Developing technicians into next generation of production engineers and technical specialists.
- Developed and implemented roadmap for modernization of aging equipment and inefficient processes. All stages have been completed according to schedule.
- Closely coordinated with commercial, technical, and management groups to secure resources and support for any equipment or process changes necessary to ensure ability to meet growing customer needs.
- Worked closely with material suppliers to ensure adherence to established requirements, and when necessary supported internal investigations and troubleshooting.
- Coordinated activities between technical groups and production teams to ensure all maintenance activities, both planned and unplanned, can be carried out in line with production needs.
Paint Process Engineer
Decostar Industries - Magna International
02.2017 - 01.2023
- Responsible for developing, launching, and maintaining several product lines across 4 OEM customers, multiple technologies, and various product types.
- Work closely with product engineering groups through product development and program launch process.
- Partnering with suppliers to develop, test, and implement new materials and processes to stay competitive in the rapidly evolving automotive industry.
- Interface directly with customers during development, launch, and production phases, ensuring all parties are aligned on goals, challenges, and solutions.
- Championed identification of KPI opportunities, providing better understanding of losses, and driving a targeted approach to reduce scrap, inefficiencies, and operating costs. Over 12 months, losses to initial quality reduced by 30%.
- Responsible for robotic programming and paint application, both in development and ongoing for assigned products. Maintain all quality requirements, root cause analysis of any recurring defects, and constant continuous improvement efforts across all steps in the manufacturing process.
- Leading ongoing efforts to improve product traceability, quality assurance, and process stability through implementation of industrialized quality verifications, automated statistical analysis, and expanding automated process controls.
- Working closely with paint suppliers and operators to improve material and process stability, incoming material approval processes, inventory management, and process flow optimization. When efforts began, process materials had expanded beyond work area, but through footprint and throughput optimization, process area has not had to expand, despite 30% increase in number of individual materials over previous 12 months.
- Working closely with fabrication and process engineering teams to develop design guidelines for paint fixtures to ensure all lessons learned are recorded and carried forward to future projects.
- Ensuring compliance with all relevant Quality, Safety, and Environmental management systems.
- Tasked with supporting business planning and resource allocation to ensure the company is positioned to be competitive with future business and technologies.
Contamination Engineer
Decostar Industries - Magna International
07.2015 - 02.2017
- Supported all production processes with defect analysis, root cause investigation, and helping drive relevant corrective actions.
- Developed defect analysis processes, training, and systems that enabled searchable databases, ability to trend issues in relation to time, location, product groups, technologies, etc. Still in use.
- Supported continuous improvement activities across all areas with process validation, feasibility studies, and FMEA analysis.
- Worked with material suppliers to validate new materials, investigate product concerns, and support implementation of new technologies.
- Interfaced with customers on product concerns, failures, and escapes, ensuring to effectively communicate technical root causes, and clearly present path for correction or prevention in future.
- Supported development of an all encompassing production control and quality assurance system.
Intern
Decostar Industries - Magna International
06.2013 - 07.2013
- Supported launch of new facility through creation of training documentation, development of process flows, and optimization of assembly methods.
- Developed process and training documentation for over 30 unique products.
- Assisted with interviewing, assessing, and training of new hires.
Skills
- Leadership in dynamic environments across multiple teams
- Strategic planning and operations
- "Reliability through design" focus
- Production process development and controls
- Engineering design and validation
- Quality, Safety, and Environmental management systems
- Materials and supply chain management
- Continuous improvement and lean manufacturing
- Fanuc Robotics and Automation
- Process flow optimization
- "Smart" data analytics (PowerBI, SQL, etc )
- CAD Design (AutoCAD, Solidworks, etc )
Timeline
Sr. Paint Process Engineer
Decostar Industries - Magna International
01.2023 - Current
Paint Process Engineer
Decostar Industries - Magna International
02.2017 - 01.2023
Contamination Engineer
Decostar Industries - Magna International
07.2015 - 02.2017
Intern
Decostar Industries - Magna International
06.2013 - 07.2013
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