Senior Advanced Manufacturing Engineer - Material Flow Optimization

Generac Power Systems Inc; North Prairie (WI); On-site; USD 95,000 - 130,000; Full time

Benefits offered by this job

Health benefits

Onsite gym

Walking trails

Free parking

Summer hours

Job summary

Generac Power Systems Inc. seeks a Senior Advanced Manufacturing Engineer focused on Material Planning & Handling. You will drive PFEP database creation, define line-side delivery strategies, and optimize end-to-end material flow from receiving to production lines.

Your work will align replenishment with takt time and support NPI through early PFEP planning. The role requires engineering experience in advanced manufacturing, cross-functional collaboration, and hands-on lean implementation using

Qualifications

• Bachelor’s degree in Engineering or Industrial Technology.
• 5 years related experience in engineering within a manufacturing environment.
• Experience with PFEP databases and material flow design is preferred.

Responsibilities

• Lead the creation and implementation of PFEP databases for complex operations.
• Design material replenishment strategies (kanban, min/max, JIT).
• Align PFEP with production takt time and line-side consumption.
• Develop PFEP tools and train plant engineers.
• Design end-to-end material flow from receiving to line-side delivery.
• Develop line feeding strategies (kitting, sequencing, POS stocking).
• Implement material handling systems (tuggers, AGVs, conveyors).
• Optimize production layouts for efficient material movement.
• Reduce touchpoints, travel time and material handling waste.
• Support NPI by defining material flow in design phase; apply Lean to material flow.
• Implement PFEP using SAP/Oracle and other ERP/MRP systems.
• Lead cross-functional workshops for PFEP rollout and flow redesign.
• Provide training to manufacturing and logistics teams on standard material processes.

Skills

PFEP databases

Material flow planning

Lean manufacturing

Cross-functional collaboration

Education

Bachelor’s degree in Engineering or Industrial Technology

Tools

SAP

Oracle

MRP systems

Job description

We believe power is a promise - a shared commitment to be there for others when it matters most.For more than 65 years, we've turned big ideas into solutions that help protect homes, strengthen businesses and build a more resilient, efficient, sustainable energy future.Ready to Power a Smarter World with us?A Senior Advanced Manufacturing Engineer with expertise in Material Planning & Handling (MPH) and PFEP execution drives point of use material flow strategy, ensuring the right material is delivered in the right quantity, at the right time, and at the lowest total cost. This role is critical in advanced manufacturing environments, directly impacting productivity, layout optimization, and production stability.Essential Duties and Responsibilities:Lead the creation and implementation of PFEP databases for complex manufacturing operations.Designed material replenishment strategies (kanban, min/max, milk-run, JIT).Ensured PFEP alignment with production takt time, line-side consumption and replenishment from HUB/WarehouseDevelop required PFEP tools, train plant engineers for effective use.Designed and optimized end-to-end material flow processes from receiving/warehouse to line-side delivery.Developed line feeding strategies (kitting, sequencing, point-of-use stocking).Implemented material handling systems (tuggers, AGVs, conveyors, manual systems).Optimized production layouts for efficient material movement.Reduced touchpoints, travel time, and material handling waste.Supported NPI (New Product Introduction) by defining material flow and PFEP early in the design phaseApplied Lean principles (5S, value stream mapping, waste elimination) to material flowImplemented or enhanced PFEP using ERP/MRP systems (SAP, Oracle, etc.).Partnered with operations, supply chain, engineering, and quality teams.Led cross-functional workshops for PFEP rollout and material flow redesign.Provided training to manufacturing and logistics teams on standard material processes.PFEP development & governanceMaterial flow design & optimizationLine-side delivery systemsLean manufacturing & continuous improvementData-driven decision makingCross-functional collaborationRequired Qualifications:Bachelor’s degree in Engineering or Industrial Technology5 years related experience in the Engineering function within a similar working environment.Office Environment: While performing the duties of this job, the employee is regularly required to talk and hear; and use hands to manipulate objects or controls. The employee is regularly required to stand and walk. On occasion, the incumbent may be required to stoop, bend, or reach above the shoulders. The employee must occasionally lift up to 25 pounds. Specific conditions of this job are typical of frequent and continuous computer-based work requiring periods of sitting, close vision, and the ability to adjust focus. Occasional travel.Great Reasons to work for Generac:Competitive Benefits: Health, Dental, Vision, 401k and many moreState-of-the-art facility with an onsite gym, walking trails, café, free parking and many employee activitiesScheduled events throughout the year that allow our employees, both current and retirees, to gather together and enjoy their time with their families and co-workersEligible for summer hours! (Memorial Day – Labor Day)Pride! When a storm strikes, Generac employees always rise to the occasion. Each time a storm hits many employees volunteer their time with the customer support team or on the production line while others go right into storm-affected areas to repair generatorsWe believe in having fun. From minor celebrations to major events, our employees balance their work by building a strong culture of teamwork and collaboration through a variety of occasions, including our Fun Days.Every day is Jeans Day! Dress for your day.Product loan and discount programs“We are an equal opportunity employer and all qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, national origin, disability status, protected veteran status, or any other characteristic protected by law.”