Staff Engineer - Reliability Quality

Rehlko•Sheboygan, WI

5d•$98,900 - $125,600•Onsite

About The Position

The Staff Engineer of Reliability & Customer Quality serves as a 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 reducing 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.

Requirements

Bachelor’s degree in Engineering (Mechanical, Electrical, Manufacturing, or related) from an ABET-accredited institution
7–10 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
Strong 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
Strong communication and presentation skills, with the ability to influence stakeholders at all levels
Proficiency with Microsoft Office tools (Excel, PowerPoint, Power BI)
Demonstrated ability to lead through influence in cross-functional environments
Applicants must be authorized to work in the US without requiring new or transfer visa sponsorship now or in the future.

Responsibilities

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 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
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
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
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
Lead cross-functional teams across Engineering, Manufacturing, Supplier Quality, Field Service, and Operations
Manage multiple concurrent initiatives of moderate to high complexity
Mentor and coach engineers, strengthening organizational capability in reliability and quality engineering
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