Director of Manufacturing

XPEL, Inc.; San Antonio (TX); On-site; USD 180,000 - 240,000; Full time

Job summary

XPEL, Inc. in San Antonio, Texas, seeks a Director of Manufacturing to lead the roll-to-roll coating, lamination, slitting and converting for its TPU-based paint protection film products.

This senior role will set technical standards, drive continuous improvement, and partner with R&D, Procurement and the partner network to scale production with quality and yield. You will mentor engineers and deliver reliable, high-quality film production.

Qualifications

• Bachelor’s degree in Chemical Engineering, Materials Science, Polymer Science, Mechanical Engineering or related technical field.
• 10+ years of manufacturing or process engineering experience in roll-to-roll coating, lamination, extrusion or converting of films or coated materials.
• 5+ years leading technical or multi-functional teams at manager or director level.
• Experience with contract manufacturers, toll coaters, converters or key suppliers.
• Track record of delivering measurable improvements in quality, yield and throughput.
• Working knowledge of coating processes, drying and curing, web handling and lamination.
• Familiarity with ISO 9001 and/or IATF 16949 quality systems and EHS practices for coating operations.
• Experience with ERP/MES systems and production data analytics.

Responsibilities

• Provide technical leadership over coating, lamination, slitting and converting for TPU-based PPF films.
• Serve as technical authority on PPF film structures, including self-healing and topcoats.
• Lead process optimization to meet coat weight, appearance and performance requirements.
• Drive Lean, Six Sigma, SPC and related continuous improvement practices.
• Lead root-cause analysis and corrective actions on defects across coating and film.
• Oversee partnerships with coating and manufacturing partners to support growth.

Skills

Leadership

Cross-functional collaboration

Quality & yield improvement

Process optimization

Communication

Travel readiness

Education

Bachelor's degree in Chemical Eng./Materials/Polymer/Mechanical

Tools

ERP/MES systems

Production data analytics

Job description

Job Summary: The Director of Manufacturing is XPEL's senior technical leader for how our paint protection film (PPF) products are produced.

Core Duties

• Provide technical leadership over roll-to-roll coating, lamination, slitting and converting processes for XPEL's paint protection film products, with a focus on TPU-based films.
• Serve as XPEL's technical authority on the PPF film structure, including self-healing and protective topcoats, pressure-sensitive adhesives, primers and release liners.
• Evaluate and optimize coating processes (such as slot-die, gravure and similar methods) to meet each product's coat weight, appearance and performance requirements.
• Guide best practices in drying, curing and web handling to ensure consistent, repeatable production.
• Ensure products consistently meet specifications for clarity, gloss, thickness, adhesion, self-healing, stain and yellowing resistance, conformability and long-term weathering performance.
• Lead root-cause analysis and corrective action on coating, adhesive and film defects, and connect field performance and installer feedback to process and material causes.
• Provide technical oversight of XPEL's network of coating, converting and manufacturing partners to ensure processes, quality and capacity support company growth.
• Lead technical qualification and onboarding of new partners, including process specifications, quality agreements, trial runs, capability studies, scorecards and audits.
• Work with Procurement and Quality on raw-material specifications (TPU film, resins, adhesives, liners), incoming inspection and supplier corrective actions, with focus on lot-to-lot variation.
• Partner with R&D and Product Management to move new PPF products from lab and pilot scale to full production, including DOE, capability validation and product qualification.
• Drive Lean, Six Sigma, SPC and related continuous improvement practices to reduce variation and improve yield, scrap, throughput, OEE and on-time delivery.
• Establish change control, process documentation (SOPs, work instructions, recipes) and FMEA/PFMEA practices across coating and converting operations.
• Build and develop a team of process and manufacturing engineers and serve as a technical mentor across XPEL and its partner network.
• Additional duties as assigned by leadership.

Basic Qualifications

• Bachelor's degree in Chemical Engineering, Materials Science, Polymer Science, Mechanical Engineering or a related technical field.
• 10+ years of manufacturing or process engineering experience, including roll-to-roll coating, laminating, extrusion or converting of films, coated materials or other flexible substrates.
• 5+ years leading technical or multi-functional teams at the manager or director level.
• Experience working with contract manufacturers, toll coaters, converters or key suppliers.
• Track record of delivering measurable improvements in quality, yield and throughput.
• Solid understanding of coating processes, drying and curing, web handling and lamination.
• Knowledge of polymer films (TPU preferred), adhesive systems and coating chemistries.
• Experience developing and enforcing product and process specifications, and with film testing methods such as adhesion, peel, gloss, thickness and weathering.
• Working knowledge of SPC, DOE, structured root-cause analysis (8D, 5-Why, Fishbone) and FMEA.
• Familiarity with ISO 9001 and/or IATF 16949 quality systems and EHS practices for coating operations.
• Experience with ERP/MES systems and production data analytics.
• Excellent communication skills with executives, R&D, partners, suppliers and production teams, with the ability to influence without direct authority.
• Ability to travel up to 50%, including internationally.

Desired Qualifications

• Advanced degree in a technical discipline
• Experience with paint protection film, TPU films or automotive exterior films and coatings
• Experience in related industries such as automotive, adhesive tapes and labels, flexible packaging or coated materials
• Lean Six Sigma Green/Black Belt or PMP certification

XPEL is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.

Since the day XPEL was founded, we’ve strived to provide the best possible products, services, and support for customers and installers alike. With a comprehensive array of offerings for automotive, watercraft, home, and office applications, there’s sure to be a solution to fit your needs.