Staff Engineer - Reliability Quality

Rehlko • Sheboygan, WI

1d

About The Position

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!
At Rehlko Power Systems (formerly Kohler Energy) is one of the world’s leading power generator manufacturers and has delivered energy solutions globally since 1920. Rehlko Power Systems offers power generation equipment for industrial, residential, mobile, and marine applications, along with automatic transfer switches, switchgear, monitoring controls, and accessories. As a Staff Engineer – Reliability Quality / Customer Quality Engineer, you will serve as a technical leader and subject matter expert responsible for improving product reliability, customer experience, and warranty performance across existing products and New Product Development (NPD). This role bridges hands‑on technical execution and strategic influence by leading complex problem‑solving efforts, mentoring engineers, and partnering cross‑functionally to proactively identify and mitigate reliability risks. The Staff Engineer plays a critical role in driving preventive and corrective actions that reduce Cost of Poor Quality (COPQ), ensure achievement of reliability and warranty targets, and support robust product releases. This position is expected to independently lead high‑impact initiatives, coach others in reliability best practices, and influence engineering, manufacturing, and supplier teams without direct authority.

Requirements

• Bachelor’s degree in Engineering (Mechanical, Electrical, Manufacturing, or related) from an ABET‑accredited institution.
• 7–10 years of applicable experience in Reliability, Quality, Design, or Manufacturing Engineering.
• 2–5 years of direct reliability or customer quality experience in industrial, automotive, engine, generator, or heavy‑equipment environments.
• Strong working knowledge of:
• Structured problem‑solving methodologies (8D, DMAIC, 5‑Whys)
• Reliability concepts, test planning, and data analysis
• Warranty and field failure analysis
• Strong written and verbal communication skills, including technical presentations to leadership.
• Proficiency with Microsoft Office tools (Excel, PowerPoint, Power BI).

Responsibilities

• Reliability Engineering & Customer Quality Leadership
• Lead reliability improvement initiatives addressing field, warranty, and customer issues with significant business or customer impact.
• Serve as a key member of the New Product Development (NPD) process, responsible for reliability test planning and closure of open incidents prior to product release.
• Assist Product Development Engineering in the identification of Critical‑to‑Quality (CTQ) characteristics and development of test plans.
• Drive reliability growth activities for NPD programs, including identification of new‑content risks and development of mitigation plans.
• Serve as a technical escalation point for complex reliability, warranty, and customer quality concerns.
• Support early warning processes by tracking new product field performance and leading containment and corrective actions as required.
• Structured Problem Solving
• Lead and facilitate advanced problem‑solving efforts using structured methodologies such as 8D, DMAIC, and related techniques.
• Drive reduction of internal and external failure costs related to design, process, supplier, or usage‑related issues.
• Ensure thorough root cause identification and implementation of sustainable corrective and preventive actions.
• Data Analysis & Statistical Methods
• Analyze warranty, field, and reliability test data to identify trends, prioritize improvement opportunities, and quantify business impact.
• Apply statistical methods including Pareto analysis, failure rate analysis, Weibull analysis, and basic reliability modeling.
• Support development of reliability targets, warranty estimates, and validation readiness for product releases.
• Product Design & Development Support
• Actively participate in and influence design reviews, including DFMEA, serviceability, robustness, and safety.
• Develop and execute reliability test plans aligned with field usage, operating environment, and risk profiles.
• As a key member of the NPD process you will verify and document closure of open reliability and customer quality issues prior to production release.
• Cross‑Functional & Project Leadership
• Lead cross‑functional teams including Design Engineering, Manufacturing Quality, Supplier Quality, Field Service, and Operations to close out quality issues.
• Plan and manage multiple concurrent projects of moderate to high technical complexity.
• Mentor and coach Engineers and early‑career Reliability Quality team members.
• Continuous Improvement & Standardization
• Contribute to the continuous improvement of Reliability Engineering processes, tools, and standard work.
• Support development, deployment, and adherence to Standard Operating Procedures and best practices.
• Act as a quality proponent and change agent across the organization.

Benefits

• Competitive compensation and benefits
• Work-life flexibility
• Recognition and rewards
• Development and career opportunities
• A safe and inclusive workplace
• a competitive salary, health, vision, dental, 401(k) with Rehlko matching, and more

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level
• Number of Employees: 501-1,000 employees