Staff Engineer-Testing

Rehlko•Kohler, WI

1d•Hybrid

About The Position

The Staff Engineer - Testing will serve as the lab’s technical authority for NVH and structural dynamics across engines, engine components, sub-assemblies and engine powered applications. Own the test strategy, standard work, and data quality for acoustic/vibration performance, fatigue/materials, and fastener/joint integrity. Provide day-to-day technical direction to technicians and analysts as an individual contributor. Develop and maintain the capability roadmap and methods spanning electrodynamic shakers, servo-hydraulic systems, strain gage instrumentation, vibration and acoustic. This role will begin onsite in Kohler, WI, with the potential to transition to a hybrid schedule after six months.

Requirements

BS in Mechanical/Aerospace/Acoustics/Vibration or related field; MS preferred.
5+ years in NVH, structural dynamics, vibration/fatigue/materials, or fastener/joint integrity, including high-speed data acquisition and advanced signal processing.
Hands-on expertise with electrodynamic shakers, servo-hydraulic systems, strain gage application, vibration and acoustic data acquisition, and specialized bench tests.
Technical leadership without formal authority; mentoring capability.
Proficiency in signal processing (time/frequency/crank angle domain analysis, PSD/FFT/FRF autospectra/cross spectra/spectrum, filtering, aliasing, sound quality equalization, integration differentiation).
Familiarity with Simcenter Testlab/3D Acoustics, Vibration Research controllers, and common DAQ platforms.
Strong communication, troubleshooting, and ability to balance multiple programs.
Applicants must be authorized to work in the US without requiring sponsorship now or in the future.

Responsibilities

Translate program targets and DFMEA risks into clear test plans, acceptance criteria, and instrumentation strategies.
Develop and maintain standard test methods, work instructions, and data‑quality criteria.
Define fixture design guidelines and instrumentation best practices.
Provide day‑to‑day technical direction to Engineering Technicians and Analysts.
Lead cross‑training across all test domains.
Assist in test set-up and data acquisition for complex cases
Provide design guidance to program teams.
Create test plans; guide fixture conceptualization; oversee complex investigations.
Perform analysis of vibration/strain/force/acoustic data and produce recommendations.
Fastener/joint integrity: bolt stretch/elongation (including ultrasonic or torque methodologies), gasket sealing (Fuji film), and joint analysis.
Materials/fatigue and tensile testing, including use of environmental chambers as required.
Plan and direct shaker-based durability and NVH tests: swept sine, random, field data replication, resonance identification and dwell.
Deliver clear engineering reports and presentation of those reports as needed.
Support prioritization and throughput; drive uptime via proactive PMs and continuous improvement of methods, fixtures, and data management.
Oversee calibration/verification for all sensors and DAQ channels.
Champion capital planning for future testing capabilities
Implement method/fixture/data improvements.
Collaborate with Rehlko Analytical Engineering Group to support and validate CAE simulation
Work with outside vendors/consultants for simulations and tests not available in-house; assess feasibility to bring capabilities in-house.
Provide clear recommendations to program teams and management; influence design decisions with sound engineering evidence.
Evaluate and apply simulation work and acquisition tools (e.g., Simcenter Testlab/3D Acoustics, Vibration View, MTS Multipurpose Elite)