De-Risk Paint Operations. Deliver Outcomes That Move Production.
Smilor Consulting helps OEMs, and Custom Coaters improve paint and powder system operations, prepare for audits, diagnose and solve persistent production issues, and develop execute complex CapEx projects — backed by 40+ years of hands-on industrial experience.
Documented results from a career on the floor.
Selected outcomes from prior engagements and leadership roles. These reflect Doug's documented experience across automotive, heavy equipment, and consumer manufacturing.
Metrics reflect documented outcomes from Doug Smilor's prior roles at Trimac Industrial Systems, Trek Bicycle, Deere & Company, and others. Brazil project recognized with Deere's Global Environmental Impact Award (2021).
When your paint line can’t afford to get it wrong.
Nearly 40 years of paint shop experience, working for you, not a vendor. From chronic quality and throughput problems to audit readiness and multi-million-dollar capital projects, Smilor Consulting brings the engineering depth and disciplined execution that protects your schedule, budget, and production, for liquid and powder coating operations in the U.S. and Mexico.
Where We Deliver Most Value
- Paint & powder system optimization: Improve OEE, throughput, yield, and finish quality on existing lines.
- Audits & compliance readiness: NFPA 33, NFPA 86, NFPA 30, and OSHA-aligned assessments with practical action plans.
- CapEx project execution: Equipment selection, vendor coordination, scope, and on-the-floor implementation.
Outcomes You Can Expect
- Stabilized lines: Disciplined root-cause analysis and standard work that holds after we leave.
- Audit-ready systems: Documented gaps, prioritized corrective actions, and clear ownership.
- Protected investments: CapEx programs that hit scope, schedule, and the operating goals behind them.
How We Engage
- Senior practitioner, not a junior team: Doug works directly on every engagement.
- Flexible scope: Single-day site visits, scoped audits, or long-term advisory.
- Industry-fluent: Automotive, heavy equipment, consumer manufacturing, and powder coating.
Specialized consulting for paint, powder &
industrial process performance.
Six service areas built around the work that actually moves throughput, quality, audit posture, and project outcomes.
Paint & Powder Process Optimization
Improve throughput, consistency, yield, and finish quality across paint and powder operations. Diagnose drift, stabilize the line, and lock in standard work that survives shift changes and operator turnover.
- OEE improvement and cycle-time reduction
- First-pass yield and rework reduction
- Class-A finish quality and process stabilization
Paint System Audits & Assessments
Evaluate existing systems, identify compliance and performance gaps, document risks, and deliver practical action plans aligned to NFPA, OSHA, and operational priorities — built for plants, not auditors' binders.
- Comprehensive paint system assessments
- NFPA 33 / 86 / 30 readiness reviews
- Prioritized corrective action plans with ownership
CapEx & Project Execution Support
Support planning, vendor coordination, equipment selection, scope definition, and on-the-floor implementation for high-stakes manufacturing investments. PMBOK-aligned discipline matched to your operating reality.
- Equipment selection and vendor management
- Project scope, schedule, and budget control
- Commissioning, ramp-up, and stabilization
Compliance & Safety Readiness
Practical guidance around paint-related standards including NFPA 33, NFPA 86, NFPA 30, and OSHA — focused on operational readiness and real-world implementation, not paperwork theater.
- NFPA paint-process compliance reviews
- OSHA safety standards alignment
- Compliance training and operator readiness
Factory Planning & Capacity Modeling
Assess production flow, capacity constraints, line balance, and operational bottlenecks. Build a plan grounded in real cycle times, real WIP, and real-world variation — not idealized takt assumptions.
- Production flow and bottleneck analysis
- Line balancing and capacity modeling
- Layout and gap closure planning
Root Cause & Turnaround Support
Help teams diagnose recurring defects, stabilize unpredictable lines, and build disciplined corrective action plans that actually hold. Built on RCA, PFMEA, and decades of implementing successful corrective actions and avoiding band aid fixes.
- Root cause analysis and PFMEA
- Production stabilization and standard work
- Turnaround leadership for stalled operations
Built by a paint systems leader who has been inside the plants, the projects, and the problems.
Smilor Consulting is led by Douglas Smilor, PMP — a Senior Technical Operations and Paint Systems leader with 40 years of experience delivering global CapEx programs, paint and powder system optimization, and large-scale manufacturing transformations.
Smilor Consulting was built to give manufacturers access to senior-level paint process expertise — without the overhead, delays, or complexity of building that capability internally. — Doug Smilor, PMP · Founder
Some of the most demanding manufacturing environments in North America.
Select a company to explore the work
Tesla
Staff Engineer, Paint supporting the Cybertruck body paint program and structural battery paint cell launch at Giga Texas.
Meet DougNames reflect Doug's prior engagements and employment history — not current client claims or endorsements.
A practical consulting process
built for industrial reality.
A structured approach to solving real-world challenges and delivering measurable results.
Assess
Understand your current state, challenges, and goals.
Analyze
Identify root causes and opportunities for improvement.
Plan
Develop practical, cost-effective solutions.
Execute
Support implementation and measure results.
Trusted by teams where quality, safety,
and execution matter.
Quotes below are placeholders during outreach to former colleagues and clients. Final endorsements will be posted once approved by their authors.
“Doug and I worked together on an important project at a global equipment manufacturer. We needed to refurbish two paint cab systems in 28 days, and we completed the challenge on time and within budget. Doug was a key contributor because he helped us with the new reconfiguration of the paint cabs. He is a very intelligent professional and made agile decisions throughout the project.
Working with Doug has always been an excellent experience. He is truly an outstanding professional, highly committed, and always eager to take on new challenges while striving for perfection. Doug brings intelligence, agility, and dedication to every project, consistently making valuable contributions that drive success.
I would be happy to work with Doug again on any project because he is not only a skilled expert but also a reliable and inspiring partner in building and executing projects.”
“Doug has started and completed projects on time that other companies would not bid. When a deadline is promised, Doug has delivered. Doug would be my first recommendation.”
“I had the opportunity to work closely with Doug, and I can confidently say he is an outstanding professional in operations and technical leadership.
He has strong expertise in NFPA standards, PMP principles, OSHA compliance, and deep knowledge of paint processes that is truly exceptional. Doug is highly skilled at building programs from the ground up, establishing SOPs, and leading teams from initial setup to full operational stability.
I strongly recommend Doug for any operations or leadership position. He consistently brings strong technical knowledge, structure, and leadership to every project he supports.”
“I had the opportunity to work closely with Doug at a leading electric vehicle manufacturer, where he consistently demonstrated a rare combination of operational rigor, strategic clarity, and hands-on leadership.
He is direct, transparent, and deeply committed to team success, qualities that are essential in high-performance cultures.
Any organization looking to scale operations, improve efficiency, or drive transformation would benefit tremendously from Doug’s leadership. I would work with him again without hesitation.”
“Doug is very knowledgeable and proficient in the area he worked for me. He was creative in overcoming issues that arose during the installation and got the job done. His expertise extends beyond the job he was working for me and I would consider him for other applications.”
“Doug worked for and with me on the installation and programming of challenging water treatment projects. He was a conscientious worker, taking the lead in getting things done efficiently and quickly. He was excellent at taking the initiative and completing difficult tasks.”
Serving industrial finishing operations.
If your operation depends on paint and powder system performance, audit posture, or the disciplined execution of complex capital projects, Smilor Consulting is built for that work.
Insights for paint process leaders.
Practical perspectives from inside the booth, the boardroom, and the budget conversation. Built for engineering, operations, and EHS leaders.
Industry experience at leading global organizations.
Real-world knowledge from working with top industrial and technology companies.
John Deere
Global paint equipment standards and capital project execution.
Harley-Davidson
High-visibility motorcycle finishing and process consistency.
Indian Motorcycle
Premium paint operations, appearance quality, and production reliability.
Need a senior paint process expert on your side?
Schedule a 30 or 60-minute consultation to discuss your paint system, audit needs, project risks, or operational challenges. Initial calls are direct, technical, and time-respectful.
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