Sr. Staff Engineer, Process Equipment, Materials Handling & Slurry Systems - (req73140)

Sterling Kohler; Wisconsin; Hybrid; USD 119,000 - 184,000; Full time

Job summary

Kohler Co. is seeking a Sr. Staff Engineer to lead process equipment, materials handling, and slurry systems across multiple sites.

You will guide complex capital projects from concept through commissioning, balancing safety, quality, cost, and schedule while mentoring engineers and collaborating with suppliers and contractors. This onsite role in Kohler, WI requires up to 30% travel, strong leadership, and deep expertise in bulk materials handling and process-fluid systems.

Qualifications

• Bachelor’s degree in mechanical, chemical, manufacturing, industrial, ceramic, or a related engineering discipline.
• 10+ years of progressive engineering experience leading complex process, equipment, manufacturing, plant-system, or capital projects with broad business impact.
• Recognized expertise in process equipment or industrial systems, including design, integration, installation, commissioning, troubleshooting, and optimization.
• Experience independently managing multiple complex projects, including scope, schedule, budget, resources, procurement, risks, milestones, and acceptance criteria.
• Advanced knowledge of bulk materials handling and process-fluid systems, including storage, conveying, feeders, pumps, piping, tanks, mixing, and distribution.
• Ability to develop and review calculations, layouts, process flow diagrams, specifications, utility requirements, controls narratives, cost estimates, schedules, and commissioning documentation.
• Strong systems thinking, technical problem-solving, project planning, risk assessment, root-cause analysis, and decision-making skills.
• Demonstrated ability to lead across functions and sites, manage external partners, establish standards, mentor technical talent, and communicate effectively with senior leaders.

Responsibilities

• Serve as the technical authority and project leader for complex process equipment, bulk material transfer, storage, batching, pumping, conveying, piping, tanks, silos, mixers, slurry distribution, utilities, and controls.
• Lead engineering and capital projects from concept and feasibility through design, procurement, installation, commissioning, validation, and operational handoff.
• Define and manage project scope, schedules, budgets, resources, risks, milestones, technical requirements, specifications, acceptance criteria, and stakeholder communications.
• Develop engineering solutions that balance safety, quality, throughput, reliability, maintainability, cost, schedule, and long-term flexibility.
• Coordinate cross-functional teams and manage engineering firms, suppliers, consultants, contractors, and system integrators.
• Lead design reviews, technical risk assessments, supplier evaluations, factory acceptance testing, installation and commissioning readiness, and project closeout.
• Monitor technical, cost, schedule, and quality performance; address variances through tradeoff decisions, recovery plans, and appropriate escalation.
• Resolve complex technical and execution issues using structured analysis, root-cause investigation, contingency planning, and sound engineering judgment.
• Influence capital and technology decisions through technical analysis, lifecycle-cost evaluation, and risk-based recommendations.
• Establish engineering and project execution standards, mentor engineers, and communicate recommendations, risks, and decisions to technical teams and senior leaders.

Skills

Process equipment

Materials handling

Slurry systems

Project leadership

Risk management

Cross-functional

Education

Bachelors degree

Job description

Sr. Staff Engineer, Process Equipment, Materials Handling & Slurry Systems

Work Mode:Onsite

Location: Onsite, four days per week - Kohler, WI

Opportunity

The Senior Staff Engineer is a recognized technical expert and project leader for process equipment, materials handling, and slurry systems. This senior individual contributor leads complex engineering and capital projects from concept through commissioning and operational handoff, combining advanced engineering judgment with disciplined management of scope, schedule, budget, resources, suppliers, and risk.

Key Responsibilities

• Serve as the technical authority and project leader for complex process equipment, bulk material transfer, storage, batching, pumping, conveying, piping, tanks, silos, mixers, slurry distribution, utilities, and controls.
• Lead engineering and capital projects from concept and feasibility through design, procurement, installation, commissioning, validation, and operational handoff.
• Define and manage project scope, schedules, budgets, resources, risks, milestones, technical requirements, specifications, acceptance criteria, and stakeholder communications.
• Develop engineering solutions that balance safety, quality, throughput, reliability, maintainability, cost, schedule, and long-term flexibility.
• Coordinate cross-functional teams and manage engineering firms, suppliers, consultants, contractors, and system integrators.
• Lead design reviews, technical risk assessments, supplier evaluations, factory acceptance testing, installation and commissioning readiness, and project closeout.
• Monitor technical, cost, schedule, and quality performance; address variances through tradeoff decisions, recovery plans, and appropriate escalation.
• Resolve complex technical and execution issues using structured analysis, root-cause investigation, contingency planning, and sound engineering judgment.
• Influence capital and technology decisions through technical analysis, lifecycle-cost evaluation, and risk-based recommendations.
• Establish engineering and project execution standards, mentor engineers, and communicate recommendations, risks, and decisions to technical teams and senior leaders.
• This role requires up to 30% travel, including international travel, for site assessments, supplier reviews, design reviews, factory acceptance testing, installation, commissioning, startup, and troubleshooting.

Skills/Requirements

• Bachelor’s degree in mechanical, chemical, manufacturing, industrial, ceramic, or a related engineering discipline.
• 10+ years of progressive engineering experience leading complex process, equipment, manufacturing, plant-system, or capital projects with broad business impact.
• Recognized expertise in process equipment or industrial systems, including design, integration, installation, commissioning, troubleshooting, and optimization.
• Demonstrated experience independently managing multiple complex projects, including scope, schedule, budget, resources, procurement, risks, milestones, and acceptance criteria.
• Advanced knowledge of bulk materials handling and process-fluid systems, including storage, conveying, feeders, pumps, piping, tanks, mixing, and distribution.
• Ability to develop and review calculations, layouts, process flow diagrams, specifications, utility requirements, controls narratives, cost estimates, schedules, and commissioning documentation.
• Strong systems thinking, technical problem-solving, project planning, risk assessment, root-cause analysis, and decision-making skills.
• Demonstrated ability to lead across functions and sites, manage external partners, establish standards, mentor technical talent, and communicate effectively with senior leaders.

Preferred Qualifications:

• Advanced engineering degree, Project Management Professional certification, or Lean Six Sigma certification.
• Experience with slurry, ceramic, mineral, chemical, wastewater, food, or other process-fluid systems.
• Experience managing large, multi-site, or international capital projects involving automation, operating-plant construction, global suppliers, or engineering contractors.
• Advanced familiarity with automation, controls, instrumentation, process monitoring, EHS requirements, contractor safety, and management of change.

#LI-BV1 #LI-Onsite

Applicants must be authorized to work in the US without requiring sponsorship now or in the future.

We believe in supporting you from the moment you join us, which is why Kohler offers day 1 benefits. This means you’ll have access to your applicable benefit programs from your first day on the job, with no waiting period. The salary range for this position is $118,650 - $183,650. The specific salary offered to a candidate may be influenced by a variety of factors including the candidate’s experience, their education, and the work location. In addition, this position is eligible for a performance bonus/variable incentive compensation.

Why Choose Kohler?

We empower each associate to #BecomeMoreAtKohler with a competitive total rewards package to support your health and wellbeing, access to career growth and development opportunities, a diverse and inclusive workplace, and a strong culture of innovation.

With more than 30,000 bold leaders across the globe, we’re driving meaningful change in our mission to help people live gracious, healthy, and sustainable lives.

About Us

It is Kohler’s policy to recruit, hire, and promote qualified applicants without regard to race, creed, religion, age, sex, sexual orientation, gender identity or expression, marital status, national origin, disability or status as a protected veteran. If, as an individual with a disability, you need reasonable accommodation during the recruitment process, please contact [e-mail]. Kohler Co. is an equal opportunity/affirmative action employer.