Senior Industrial Engineer - Genset Assembly & Packaging

Generac Power Systems•Waukesha, WI

7d•Onsite

About The Position

The Senior Industrial Engineer is the technical authority responsible for designing, optimizing, and transforming manufacturing systems for generator production and genset enclosing operations. This role drives strategic improvements across assembly, enclosure fabrication, fuel systems, cooling packages, wiring integration, and final packaged‑unit build. The engineer will architect world‑class manufacturing processes, deploy advanced automation, and lead cross‑functional initiatives that elevate throughput, quality, safety, and cost performance across the entire value stream. This position is ideal for a senior‑level engineer who blends deep industrial engineering expertise, systems engineering thinking, and hands‑on operational leadership.

Requirements

Bachelor’s degree in Engineering or Industrial Technology
5 years related experience in the Engineering function within a similar working environment.

Nice To Haves

Experience with generator manufacturing, genset packaging, or power systems integration.
Knowledge of fuel systems, cooling packages, Engine Assembly, Fabrication and electrical testing.
Familiarity with ERP/MRP systems (SAP).
Experience in digital manufacturing, IIoT, or Industry 4.0 initiatives.

Responsibilities

Design and optimize end‑to‑end manufacturing systems for generator assembly and complete genset packaging (skids, enclosures, tanks, cooling systems).
Develop long‑term capacity strategies, including equipment selection, automation roadmaps, and plant‑wide layout evolution.
Build digital twins and simulation models(Arena, Flex SIM) to predict bottlenecks, labor requirements, and capital needs.
Partner with Quality to reduce defects in generator assembly, wiring harnesses, and final assembly.
Lead high‑precision process development for Assembly, Electrical Integration and Packaging Processes.
Implement advanced industrial engineering tools: MTM, DOE, SPC, PFMEA, and process validation.
Engineer fixtures, jigs, and tooling to improve repeatability and reduce ergonomic risk.
Drive enterprise‑level Lean transformation across generator manufacturing and packaging operations.
Lead VSM events that span fabrication, assembly, testing, and logistics.
Deploy SMED, 5S, Kanban, Heijunka, and standardized work at a systems level.
Identify and implement automation solutions such as Cobots, AGVs, and automated test systems.
Collaborate with controls and IT teams to advance digital manufacturing maturity.
Lead cost‑out initiatives involving material usage, takt‑time reduction, design simplification, and supply chain alignment.
Conduct make‑vs‑buy analysis for subassemblies and enclosure components.
Support DFM/DFA for new generator models and enclosure designs.
Serve as the technical bridge between Engineering, Operations, Supply Chain, Quality, and Facilities.
Lead major capital projects, including new line installations, new plant setup, layout redesigns, and technology upgrades.
Mentor junior engineers and develop the next generation of industrial engineering talent.