Tool & Die Maker - 1st Shift

Generac; Beaver Dam (WI); On-site; USD 50,000 - 70,000; Full time

Job summary

Generac is looking for a Tool & Die Maker at its Beaver Dam facility to support the production of alternators through expert-level tooling and machine troubleshooting. The role includes building, repairing, and modifying dies and fixtures, diagnosing complex equipment issues, and leading continuous improvement efforts to enhance reliability and production efficiency. The ideal candidate has over 5 years of experience and is skilled in precision machining and troubleshooting. This position offers opportunities for significant impact on production outcomes.

Qualifications

• 5+ years of Tool & Die Maker experience in a manufacturing environment.
• Demonstrated ability to troubleshoot complex mechanical systems.
• Proven capability to redesign and fabricate machine components.

Responsibilities

• Build, repair, modify, and maintain dies and fixtures.
• Troubleshoot proprietary machinery and custom-built equipment.
• Design and implement improvements that increase uptime.

Skills

Troubleshooting complex mechanical systems

Blueprint reading

Precision machining

Tool & Die Making

Continuous improvement

Education

High School Diploma or GED

Job description

1st Shift: Monday - Thursday 5:00AM - 3:30PM

Position Summary

The Tool & Die Maker at the Beaver Dam facility plays a critical, highly autonomous role in supporting the production of alternators through expert-level tooling, machine troubleshooting, and continuous improvement. This position is responsible for diagnosing and resolving complex issues on proprietary manufacturing equipment, often where documentation is limited or non-existent. The role requires the ability to independently redesign, modify, and improve machine assemblies, tooling, and components to enhance reliability, quality, and throughput. The Tool & Die Maker is expected to operate as a technical authority within the facility, driving improvements with minimal direction and strong ownership of outcomes.

Core Responsibilities

Proprietary Equipment & Tooling Support (Primary)

• Build, repair, modify, and maintain dies, fixtures, gauges, jigs, and specialized tooling used in alternator manufacturing
• Troubleshoot highly complex, proprietary machinery and custom-built equipment unique to Generac operations
• Diagnose root causes related to alignment, tolerance stack-up, wear, vibration, heat, and mechanical interaction
• Independently redesign and rework machine assemblies or components when standard repairs are insufficient
• Perform precision fitting, grinding, machining, and hand work to extremely tight tolerances

Machining & Fabrication Expertise

• Operate manual and CNC machining equipment including mills, lathes, grinders
• Manufacture replacement parts and custom components using prints, sketches, measurements, or reverse engineering
• Interpret complex blueprints, GD&T, and engineering intent to ensure functional accuracy

Continuous Improvement & Technical Ownership

• Take full ownership of tooling and machine performance within assigned manufacturing areas
• Proactively identify chronic equipment issues and lead permanent corrective actions
• Design and implement improvements that increase uptime, reduce scrap, and improve process stability
• Challenge existing designs and processes, proposing innovative mechanical solutions without reliance on external support
• Support new product introductions and process changes by designing or modifying tooling and machine components
• Provide expert-level guidance to Maintenance, Engineering, and Production when complex mechanical decisions are required

Safety, Documentation & Collaboration

• Adhere to all safety standards including machine guarding, LOTO, and toolroom best practices
• Document tool modifications, machine changes, and improvement actions to support long-term reliability
• Partner with Manufacturing Engineering to align improvements with process intent and production goals
• Mentor and support skill development within the toolroom and broader operations team

Required Qualifications

• High School Diploma or GED
• 5+ years of Tool & Die Maker, toolroom, or precision machining experience in a manufacturing environment
• Demonstrated ability to independently troubleshoot complex mechanical systems and proprietary equipment
• Proven capability to redesign and fabricate machine components with little or no assistance
• Advanced blueprint reading and GD&T interpretation skills

Preferred Qualifications

• Journeyman Tool & Die Maker certification or completed apprenticeship
• Experience supporting alternator, motor, or other rotating equipment manufacturing
• Background in automated or semi-automated assembly processes
• Demonstrated leadership in continuous improvement or equipment reliability initiatives

Physical & Work Environment Requirements

• Ability to stand, bend, reach, and work at machines for extended periods
• Ability to lift up to 50 lbs and handle precision components safely
• Comfortable working around machining equipment, rotating machinery, oils, coolants, and metal chips

What Success Looks Like at Beaver Dam

• Proprietary alternator production equipment operates with high reliability and repeatability
• Chronic tooling and machine issues are eliminated through effective redesign, not temporary fixes
• Continuous improvement efforts result in measurable gains in uptime, quality, and throughput
• The Tool & Die Maker is trusted as a primary technical problem-solver and improvement leader