Senior Staff Engineer - Manufacturing En

Rehlko; Kenosha (WI); On-site; USD 110,000 - 160,000; Full time

Benefits offered by this job

Competitive compensation

Work-life flexibility

Recognition and rewards

Career development

Safe workplace

Job summary

Rehlko in Kenosha, WI is seeking a Senior Staff Engineer - Manufacturing Engineering to drive site performance across safety, quality, delivery, cost, and productivity. You will own cross-functional execution in a small-site environment, including CAPEX projects, new product integration, systems implementation, and operational readiness.

Responsibilities include leading process improvements, optimizing workflows, and partnering with design to ensure manufacturability.

Qualifications

• Senior manufacturing engineering experience in a site-wide role.
• Experience leading capital projects (CAPEX).
• Strong Lean/continuous improvement experience (DMAIC, PDCA, A3).

Responsibilities

• Drive production performance by ensuring efficient operations, meeting output goals, and maintaining high-quality standards.
• Establish and optimize manufacturing processes, workflows, and material flow to maximize throughput, efficiency, and scalability.
• Identify and implement process improvements to enhance safety, quality, productivity, and cost efficiency, ensuring rapid containment, root cause identification, and permanent corrective actions.
• Lead continuous improvement initiatives using Lean methodologies (DMAIC, PDCA, A3). Implement error-proofing (Poka-Yoke), standardized work, and visual management systems.
• Partner with design engineering to ensure products are optimized for manufacturability (DFM/DFA) and support new product launches.
• Develop and maintain manufacturing processes, routings, and material flow to maximize throughput and resource utilization.
• Own and lead capital projects (CAPEX) from concept through implementation, including budgeting, vendor selection, installation, and validation.
• Serve as the primary project manager for site-level initiatives, ensuring timelines, cost, and scope are met

Tools

CAPEX budgeting

Job description

JOB REQUIREMENTS: 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 Location: Onsite (Kenosha, WI)

The Senior Staff Engineer - Manufacturing Engineering is a key technical and operational leader responsible for driving overall site performance across safety, quality, delivery, cost, and productivity. This role goes beyond traditional manufacturing engineering by owning cross-functional execution in a small-site environment, including capital projects, new product integration, systems implementation, and operational readiness.

Specific Responsibilities:

• Drive production performance by ensuring efficient operations, meeting output goals, and maintaining high-quality standards.
• Establish and optimize manufacturing processes, workflows, and material flow to maximize throughput, efficiency, and scalability.
• Identify and implement process improvements to enhance safety, quality, productivity, and cost efficiency, ensuring rapid containment, root cause identification, and permanent corrective actions
• Lead continuous improvement initiatives using Lean methodologies (DMAIC, PDCA, A3). Implement error-proofing (Poka-Yoke), standardized work, and visual management systems.
• Partner with design engineering to ensure products are optimized for manufacturability (DFM/DFA) and support new product launches.
• Develop and maintain manufacturing processes, routings, and material flow to maximize throughput and resource utilization.
• Own and lead capital projects (CAPEX) from concept through implementation, including budgeting, vendor selection, installation, and validation.
• Serve as the primary project manager for site-level initiatives, ensuring timelines, cost, and scope are met