Senior Manufacturing Engineer – Paint

Lotus Cars is renowned for crafting world-class, high-performance, and lightweight sports cars that are celebrated across the globe.

Lotus Cars Limited serves as the company’s manufacturing HQ in the UK, where we proudly produce iconic models such as the Emira and the all-electric Evija. As we continue to elevate our capabilities and global presence, we are seeking a Senior Manufacturing Engineer – Paint to join our dynamic Paint team at our state-of-the-art manufacturing facility in Hethel.

Summary

The Senior Manufacturing Engineer – Paint is responsible for developing, optimising and maintaining robust paint manufacturing processes that deliver world-class quality, safety, cost and delivery performance. Working within a high-volume automotive OEM environment, the role provides technical leadership across paint operations, supporting current production, new model introductions and continuous improvement initiatives while ensuring compliance with customer, industry and environmental standards.

What You'll Do

Key Responsibilities

• Lead the development, optimisation and continuous improvement of paint manufacturing processes to maximise quality, efficiency, throughput and equipment reliability.
• Provide technical ownership of paint application processes, including pretreatment, e-coat, primer, basecoat, clearcoat and associated curing systems where applicable.
• Support new model introductions, engineering changes and product launches, ensuring paint processes are developed, validated and introduced successfully.
• Specify, procure, commission and validate new paint equipment and manufacturing systems, including supplier management, Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT).
• Investigate and resolve paint process and product quality concerns using structured problem-solving methodologies, identifying root causes and implementing robust corrective and preventive actions.
• Analyse and reduce paint defects including dirt inclusions, runs, sags, orange peel, adhesion failures, colour variation and surface finish concerns.
• Develop, maintain and continuously improve Process Flow Diagrams, PFMEAs, Control Plans, standard operating procedures and manufacturing documentation in accordance with APQP and PPAP requirements.
• Collect, analyse and maintain Control Plan data to monitor process capability, identify trends and ensure ongoing compliance with quality standards.
• Plan, conduct and evaluate paint material and process validation activities, including coating performance testing such as stone chip resistance, cross-hatch adhesion, jet wash adhesion, humidity resistance, chemical resistance and thermal durability, ensuring products meet both customer and internal performance requirements.
• Interpret test results, recommend process or material improvements and work closely with suppliers and product engineering teams to deliver robust, production-ready solutions.
• Manage paint process capability through statistical analysis, process monitoring and data-driven continuous improvement activities.
• Ensure manufacturing equipment, measuring devices and test equipment are calibrated, maintained and fit for purpose, with accurate calibration records and process data maintained in accordance with quality management requirements.
• Maintain accurate engineering records, process documentation and validation reports to support product traceability, regulatory compliance and continuous improvement.
• Ensure the Paint Shop remains audit-ready by maintaining compliance with ISO 9001 quality management requirements and supporting internal, customer and third-party audits through effective documentation, process control and corrective action management.
• Drive Lean Manufacturing, Six Sigma and waste reduction initiatives to improve Overall Equipment Effectiveness (OEE), First Time Through (FTT), Right First Time (RFT), material utilisation, energy efficiency and environmental performance.
• Support capital investment projects from concept through implementation, ensuring projects are delivered safely, on time and within budget.
• Collaborate closely with Production, Quality, Maintenance, Product Engineering, Purchasing and external suppliers to resolve technical issues and implement process improvements.
• Ensure all paint processes comply with Health, Safety and Environmental legislation, including COSHH requirements, environmental permits and internal company standards.
• Monitor and report key manufacturing KPIs, presenting technical data and improvement plans to engineering and operational leadership teams.
• Provide technical leadership, coaching and mentoring to manufacturing engineers, technicians and production teams, promoting engineering best practice across the Paint Shop.
• Identify and deliver cost reduction opportunities through process optimisation, material efficiency improvements, equipment upgrades and waste elimination initiatives.