Senior Advanced Manufacturing Engineer - Process Optimization

generac; Waukesha (WI); On-site; USD 110,000 - 160,000; Full time

Benefits offered by this job

Competitive Benefits: Health, Dental,

Vision, 401k and more

Employee activities and events

Pride! Storm relief volunteering

Job summary

Generac is seeking a Senior Advanced Manufacturing Engineer to design, optimize, and transform generator manufacturing systems. You will build digital twins, drive capacity planning, and lead cross-functional Lean initiatives across assembly, enclosure, and packaging.

The role emphasizes deep engineering expertise, systems thinking, and hands-on leadership to improve throughput, quality, safety, and costs. Ideal for senior engineers with a track record in industrial environments.

Qualifications

• Bachelor's degree in Engineering or Industrial Technology required.
• 5 years related experience in the Engineering function within a similar working environment.
• Experience with generator manufacturing, genset packaging, or power systems integration preferred.

Responsibilities

• Design end-to-end manufacturing systems for generator assembly and genset packaging.
• Lead advanced process engineering and tooling to improve repeatability and reduce risk.
• Drive Lean transformations: SMED, 5S, Kanban and standardized work at system level.
• Identify and deploy automation ideas (Cobots, AGVs) and digital manufacturing maturity.

Skills

Systems thinking

Analytical problem solving

Project management

Influence at all levels

Education

Bachelor's degree in Engineering or Industrial Technology

Tools

SAP ERP/MRP

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?

The Senior Advanced Manufacturing Engineer is the technical authority responsible for designing, optimizing, and transforming manufacturing systems for generator production and genset enclosing operations. This role drives strategic improvements across assembly, enclosure fabrication, fuel systems, cooling packages, wiring integration, and final packaged‑unit build. The engineer will architect world‑class manufacturing processes, deploy advanced automation, and lead cross‑functional initiatives that elevate throughput, quality, safety, and cost performance across the entire value stream.

This position is ideal for a senior‑level engineer who blends deep industrial engineering expertise, systems engineering thinking, and hands‑on operational leadership

Core Responsibilities

• Manufacturing Systems ArchitectureDesign and optimize end‑to‑end manufacturing systems for generator assembly and complete genset packaging (skids, enclosures, tanks, cooling systems). Develop long‑term capacity strategies, including equipment selection, automation roadmaps, and plant‑wide layout evolution. Build digital twins and simulation models(Arena, Flex SIM) to predict bottlenecks, labor requirements, and capital needs. Partner with Quality to reduce defects in generator assembly, wiring harnesses, and final assembly
• Advanced Process EngineeringLead high‑precision process development for Assembly, Electrical Integration and Packaging Processes. Implement advanced industrial engineering tools: MTM, DOE, SPC, PFMEA, and process validation. Engineer fixtures, jigs, and tooling to improve repeatability and reduce ergonomic risk.
• Lean Enterprise LeadershipDrive enterprise‑level Lean transformation across generator manufacturing and packaging operations. Lead VSM events that span fabrication, assembly, testing, and logistics. Deploy SMED, 5S, Kanban, Heijunka, and standardized work at a systems level.
• Automation & Technology IntegrationIdentify and implement automation solutions such as Cobots, AGVs, and automated test systems. Collaborate with controls and IT teams to advance digital manufacturing maturity.
• Cost Optimization & Value EngineeringLead cost‑out initiatives involving material usage, takt‑time reduction, design simplification, and supply chain alignment. Conduct make‑vs‑buy analysis for subassemblies and enclosure components Support DFM/DFA for new generator models and enclosure designs.
• Cross‑Functional LeadershipServe as the technical bridge between Engineering, Operations, Supply Chain, Quality, and Facilities. Lead major capital projects, including new line installations, new plant setup, layout redesigns, and technology upgrades. Mentor junior engineers and develop the next generation of industrial engineering talent.

Required Qualifications

• Bachelor's degree in Engineering or Industrial Technology
• 5 years related experience in the Engineering function within a similar working environment.

Preferred Qualifications

• Experience with generator manufacturing, genset packaging, or power systems integration.
• Knowledge of fuel systems, cooling packages, Engine Assembly, Fabrication and electrical testing.
• Familiarity with ERP/MRP systems (SAP).
• Experience in digital manufacturing, IIoT, or Industry 4.0 initiatives.

Key Competencies

• Systems‑level thinking and strategic planning
• Strong analytical and problem‑solving capability
• Ability to influence at all organizational levels
• Exceptional communication and project‑management skills
• Hands‑on, shop‑floor‑driven leadership style
• Continuous‑improvement mindset with a bias for action

Physical Demands:

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 - 50 pounds. Specific conditions of this job are typical of frequent and continuous computer‑based work requiring periods of sitting, close vision and ability to adjust focus.

Great Reasons to work for Generac:

• Competitive Benefits: Health, Dental, Vision, 401k and many more
• Many employee activities
• Scheduled events throughout the year that allow our employees, both current and retirees, to gather together and enjoy their time with their families and co-workers
• 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