Senior Industrial Engineer - Material Flow Design and Optimization

Generac Power Systems; Waukesha (WI); On-site; USD 75,000 - 110,000; Full time

Benefits offered by this job

Health benefits

Onsite gym

Free parking

Jeans Day

Team events

Job summary

Generac Power Systems is seeking a Senior Industrial Engineer with expertise in Material Planning & Handling (MPH) and PFEP execution to drive point of use material flow strategy. The role focuses on delivering the right material, at the right time, at lowest total cost, impacting productivity and production stability.

Responsibilities include PFEP development, kanban and JIT strategies, line-side delivery, and Lean improvements.

Qualifications

• Bachelor’s degree in Engineering or Industrial Technology required.
• 5 years related experience in engineering within a similar manufacturing environment.

Responsibilities

• Lead PFEP databases creation & implementation 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.
• Optimize end-to-end material flow from receiving to line-side delivery.
• Lead cross-functional PFEP rollout workshops and train teams on material processes.

Skills

PFEP development

Material flow design

Lean manufacturing

Data-driven decisions

Cross-functional collaboration

Line-side delivery

Production layout optimization

Education

Bachelor's degree in Engineering or Industrial Technology

Tools

SAP

Oracle ERP

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 Industrial 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/Warehouse
• Develop 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 phase
• Applied Lean principles (5S, value stream mapping, waste elimination) to material flow
• Implemented 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 & governance
• Material flow design & optimization
• Line-side delivery systems
• Lean manufacturing & continuous improvement
• Data-driven decision making
• Cross-functional collaboration

Required Qualifications:

• Bachelor’s degree in Engineering or Industrial Technology
• 5 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 more
• State-of-the-art facility with an onsite gym, walking trails, café, free parking and 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
• Eligible 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 generators
• We 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.”