Senior Staff Engineer - Manufacturing Engineering
Job Description
Our work is guided by our purpose: creating an energy-resilient world for a better future. This purpose embodies the legacy we bring, with more than 100 years as the global leader in energy resilience, delivering solutions critical to sustain and improve life.
Our teams have the opportunity to provide a critical resource – energy – that ensures safety, security, and independence for people around the world. Our team members are focused on pushing boundaries, continuing to innovate in an ever-changing landscape, and keeping up with the pace required to create solutions for today’s world demands.
Our product range includes engines, generators, power conversion, UPS systems, EV components and electrification solutions, microgrid controls and management, and clean energy solutions that serve a broad spectrum of OEM, residential, industrial, and commercial customers. At Rehlko, you have the freedom to identify, create, and deliver solutions – large and small – that help people and communities thrive in the moments that matter.
At Rehlko, our team members are the essential energy that powers our organization’s success. We are committed to fostering a safe and sustainable work environment where safety is everyone’s responsibility. We empower every team member to actively participate in our Zero Is Possible safety culture by encouraging open communication, proactively reporting hazards, following protocols, and suggesting improvements. Join us in creating an energy resilient world for a better future!
What We Offer
At Rehlko, our Total Rewards programs are designed to accelerate growth, energize performance, and support a culture of inclusion at every stage of life and work. We offer total rewards that are easily understood, recognize results, enable career mobility, and reflect our commitment to valuing diverse needs in a fast-moving world. We provide:
Competitive compensation and benefits
Work-life flexibility
Recognition and rewards
Development and career opportunities
A safe and inclusive workplace
Why You Will Love this Job
Location: Onsite (Kenosha, WI)
The Senior Staff Engineer - Manufacturing Engineering is a key technical and operational leader responsible for driving overall site performance across safety, quality, delivery, cost, and productivity. This role goes beyond traditional manufacturing engineering by owning cross-functional execution in a small-site environment, including capital projects, new product integration, systems implementation, and operational readiness.
Specific Responsibilities:
Drive production performance by ensuring efficient operations, meeting output goals, and maintaining high-quality standards.
Establish and optimize manufacturing processes, workflows, and material flow to maximize throughput, efficiency, and scalability.
Identify and implement process improvements to enhance safety, quality, productivity, and cost efficiency, ensuring rapid containment, root cause identification, and permanent corrective actions
Lead continuous improvement initiatives using Lean methodologies (DMAIC, PDCA, A3). Implement error-proofing (Poka-Yoke), standardized work, and visual management systems.
Partner with design engineering to ensure products are optimized for manufacturability (DFM/DFA) and support new product launches.
Develop and maintain manufacturing processes, routings, and material flow to maximize throughput and resource utilization.
Own and lead capital projects (CAPEX) from concept through implementation, including budgeting, vendor selection, installation, and validation.
Serve as the primary project manager for site-level initiatives, ensuring timelines, cost, and scope are met
Lead end-to-end industrialization of new products
Partner with design engineering to ensure strong DFM/DFA alignment
Own production readiness, including tooling, process capability, operator training, and documentation
Perform other duties as assigned.
Requirements:
Bachelor of Science (from an ABET accredited institution) in Mechanical Engineering, Industrial Engineering, Manufacturing Engineering, or related technical field.
5+ years of relevant experience in manufacturing, process engineering, or project engineering.
Proven experience owning projects and delivering measurable results.
Advanced problem-solving capability at both system and subsystem levels.
Experience leading capital projects and equipment implementation.
Strong mechanical and process aptitude.
Excellent communication and interpersonal skills and ability to lead cross-functional teams.
Lean Six Sigma Green Belt (or equivalent demonstrated experience); Black Belt preferred
Experience drawing accurate conclusions from test data, malfunctions, or deviations, and assisting with corrections to the existing design or process preferred.
Ability to manage multiple projects of moderate scope and complexity at the same time while managing high-priority initiatives as needed.
Be innovative, resourceful, and work with minimal direction.
Applicants must be authorized to work in the US without requiring sponsorship now or in the future.
About Us
Rehlko proudly offers a rich history steeped in creativity and commitment to our associates and communities, along with competitive benefits and compensation. Our Purpose—Creating an energy resilient world for a better future—and Values: Curiosity, Trust, Pace, and Excellence, are important cultural components that shape the way we work and relate to one another. Learn more about Rehlko at http://www.rehlko.com/who-we-are.
In addition to the investment in your development, Rehlko offers a benefits package including a competitive salary, health, vision, dental, 401(k) with Rehlko matching, and more!?
Rehlko is an equal opportunity employer that prohibits discrimination and will make decisions regarding employment opportunities, including, but not limited to, hiring, job assignment, compensation, promotion, benefits, training, discipline, and termination, without regard to race, creed, color, ethnicity, religion, sex, pregnancy, childbirth, or related medical conditions, genetic information, age, national origin, citizenship, ancestry, caste, mental or physical disability, marital or familial status, sexual orientation, gender identity or expression, genetic information, political belief or affiliation, union membership status, military status, veteran status, or any other characteristic protected by national, state, local, or other applicable laws.
Americans with Disabilities Act (ADA)
It is the policy of Rehlko to comply with all applicable provisions of the Americans with Disabilities Act (ADA) and corresponding national, state, local, or other applicable laws. Rehlko will not discriminate against any qualified associate or applicant with respect to any terms, privileges, or conditions of employment because of a person's physical or mental disability. Rehlko will provide a reasonable accommodation to associates or applicants with disabilities, in accordance with applicable laws. If you have a disability and require an accommodation in the application process or during the course of employment, please contact [email protected]. Rehlko is an equal opportunity/affirmative action employer.
Our Values
Curiosity – Seek, learn, share
Trust – Go farther together
Pace – Focus to go faster
Excellence – Find the win every day