Senior Project Engineer of Reliability & Customer Quality

Rehlko Company; Sheboygan, Northern (WI, KY); Hybrid; USD 90,000 - 114,000; Full time

Benefits offered by this job

Competitive compensation

Work-life flexibility

Recognition and rewards

Career development

Inclusive workplace

Job summary

Rehlko Company in Sheboygan, WI is seeking a Senior Project Engineer of Reliability & Customer Quality to lead high-impact reliability initiatives and improve warranty performance across existing products and New Product Development.

You will collaborate with product development to define CTQ characteristics, validate designs, and drive robust reliability test plans aligned with real-world operating conditions.

Qualifications

• Bachelor’s degree in Engineering from an ABET-accredited program.
• 5–7 years of experience in Reliability, Quality, Design, or Manufacturing Engineering.
• 2–5 years of direct reliability or customer quality experience within industrial, automotive, engine, generator, or heavy equipment environments.

Responsibilities

• Co-lead high-impact reliability improvement initiatives addressing field, warranty, and customer issues.
• Partner with Product Development to identify CTQ characteristics and develop validation plans.
• Drive reliability growth strategies and risk 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.
• Influence design reviews including DFMEA, robustness, serviceability, and safety considerations.

Skills

Strong communication

Presentation skills

Data analysis

Education

ABET-accredited bachelor’s degree in engineering

Tools

Excel

PowerPoint

Power BI

Job description

## Senior Project Engineer of Reliability & Customer QualityApply: Onsite: Sheboygan,WI: Full time: Posted Today: R04797Why Work at RehlkoOur 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, tools, and standard work* Support development and deployment of best practices and standard operating procedures* Act as a champion for quality and continuous improvement across the organization**Requirements:*** Bachelor’s degree in Engineering (Mechanical, Electrical, Manufacturing, or related) from an ABET-accredited institution* 5-7 years of experience in Reliability, Quality, Design, or Manufacturing Engineering* 2–5 years of direct experience in reliability or customer quality within industrial, automotive, engine, generator, or heavy equipment environments**Technical Expertise preferred:*** knowledge of structured problem-solving methodologies (**8D, DMAIC, 5-Whys**)* Experience with reliability engineering principles, test planning, and data analysis* Background in warranty analysis and field failure investigation**Additional Skills:*** Strong communication and presentation skills, with the ability to influence stakeholders at all levels* Proficiency with Microsoft Office tools (Excel, PowerPoint, Power BI)The Salary range for this position is $89,800.00-$114,100.00.The specific Salary rate offered to a candidate may be influenced by a variety of factors including the candidate’s experience, their education, and the work location.