Senior Project Engineer of Reliability & Customer Quality

Kohler (Rehlko); Sheboygan (WI); On-site; USD 95,000 - 130,000; Full time

Benefits offered by this job

Relocation assistance available

Onsite work

Job summary

Rehlko in Sheboygan, Wisconsin, seeks a Senior Project Engineer of Reliability & Customer Quality to lead strategic reliability initiatives, improve product performance, and bolster warranty outcomes across existing products and New Product Development.

You will drive cross-functional problem solving, mentor engineering teams, and partner with Product Development to define CTQs, validate designs, and ensure on-time, robust product launches.

Qualifications

• Experience in reliability projects and field data analysis.
• Proven track record in root cause analysis and corrective actions.
• Experience with DFMEA and product design reviews.

Responsibilities

• Lead reliability engineering and customer quality leadership initiatives.
• Co-lead high-impact reliability improvement projects addressing field and warranty issues.
• Support NPD processes to define CTQs and validate reliability before release.
• Develop robust validation plans with Product Development teams.
• Drive risk identification and mitigation for new technologies and designs.
• Lead advanced problem-solving efforts using 8D, DMAIC, and 5-Whys.
• Monitor field performance and coordinate containment and corrective actions.

Skills

Reliability engineering

Problem solving

Cross-functional collaboration

Job description

Why Work at Rehlko

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

The Senior Project Engineer of Reliability & Customer Quality to serve as a support technical leader focused on improving product reliability, enhancing customer experience, and driving warranty performance across both existing products and New Product Development (NPD).

This role combines deep technical expertise with strategic influence , leading complex problem-solving initiatives, mentoring engineering talent, and partnering cross-functionally to proactively identify and mitigate reliability risks. You will play a critical role in assisting with reducing the Cost of Poor Quality (COPQ), ensuring successful product launches, and driving continuous improvement across the organization.

This opportunity is ideal for an experienced engineer who thrives in a high-impact role, enjoys solving complex challenges, and can influence outcomes across teams without direct authority.

Work mode: Onsite-Monday-Friday

Location: N7650 County Rd LS, Sheboygan, WI, 53083

Relocation assistance available

Key Responsibilities

• Reliability Engineering & Customer Quality Leadership
• Co-lead high-impact reliability improvement initiatives addressing field, warranty, and customer issues
• Serve as a key contributor within the NPD process, ensuring reliability requirements are defined, validated, and achieved prior to product release
• Partner with Product Development teams to identify Critical-to-Quality (CTQ) characteristics and develop robust validation plans
• Drive reliability growth strategies, including risk identification and mitigation for new technologies and designs
• Act as a support technical escalation point for complex reliability and customer quality concerns
• Monitor early field performance of new products and lead containment and corrective actions as needed
• Structured Problem Solving
• Co-lead and facilitate advanced problem-solving efforts using methodologies such as 8D, DMAIC, and 5-Whys
• Drive reduction of internal and external failure costs through root cause analysis and sustainable corrective actions
• Ensure disciplined execution of preventive and corrective measures across design, manufacturing, and supplier-related issues
• Data Analysis & Reliability Methods
• Analyze warranty, field, and test data to identify trends, prioritize actions, and quantify business impact
• Apply statistical tools such as Pareto analysis, Weibull analysis, and reliability modeling
• Support development of reliability targets, warranty projections, and product validation readiness
• Product Development & Design Support
• Influence design reviews, including DFMEA, robustness, serviceability, and safety considerations
• Develop and execute reliability test plans aligned with real-world operating conditions and risk profiles
• Ensure closure of all reliability and customer quality issues prior to production release
• Continuous Improvement & Standardization
• Drive enhancements to reliability engineering processes,