Senior Staff Engineer - Manufacturing Engineering

About the role

The Senior Staff Engineer - Manufacturing Engineering is a key technical and operational leader responsible for driving overall site performance across safety, quality, delivery, cost, and productivity. This role goes beyond traditional manufacturing engineering by owning cross-functional execution in a small-site environment, including capital projects, new product integration, systems implementation, and operational readiness.

Responsibilities

• Drive production performance by ensuring efficient operations, meeting output goals, and maintaining high-quality standards.
• Establish and optimize manufacturing processes, workflows, and material flow to maximize throughput, efficiency, and scalability.
• Identify and implement process improvements to enhance safety, quality, productivity, and cost efficiency, ensuring rapid containment, root cause identification, and permanent corrective actions.
• Lead continuous improvement initiatives using Lean methodologies (DMAIC, PDCA, A3).
• Implement error-proofing (Poka-Yoke), standardized work, and visual management systems.
• Partner with design engineering to ensure products are optimized for manufacturability (DFM/DFA) and support new product launches.
• Develop and maintain manufacturing processes, routings, and material flow to maximize throughput and resource utilization.
• Own and lead capital projects (CAPEX) from concept through implementation, including budgeting, vendor selection, installation, and validation.
• Serve as the primary project manager for site-level initiatives, ensuring timelines, cost, and scope are met.
• Lead end-to-end industrialization of new products.
• Partner with design engineering to ensure strong DFM/DFA alignment.
• Own production readiness, including tooling, process capability, operator training, and documentation.
• Perform other duties as assigned.

Requirements

• Bachelor of Science (from an ABET accredited institution) in Mechanical Engineering, Industrial Engineering, Manufacturing Engineering, or related technical field.
• 5+ years of relevant experience in manufacturing, process engineering, or project engineering.
• Proven experience owning projects and delivering measurable results.
• Advanced problem-solving capability at both system and subsystem levels.
• Experience leading capital projects and equipment implementation.
• Strong mechanical and process aptitude.
• Excellent communication and interpersonal skills and ability to lead cross-functional teams.
• Leverage Lean Six Sigma Green Belt (or equivalent demonstrated experience); Black Belt preferred.
• Experience drawing accurate conclusions from test data, malfunctions, or deviations, and assisting with corrections to the existing design or process preferred.
• Able to manage multiple projects of moderate scope and complexity at the same time while managing high-priority initiatives as needed.
• Be innovative, resourceful, and work with minimal direction.

What We Offer

• Competitive compensation and benefits.
• Work-life flexibility.
• Recognition and rewards.
• Development and career opportunities.
• A safe and inclusive workplace.

Pay

The specific Salary rate offered to a candidate may be influenced by a variety of factors including the candidate’s experience, their education, and the work location. The Salary range for this position is $113,000.00-$143,950.00.

Schedule

Location: Onsite (Kenosha, WI)

Benefits

• Health, vision, dental insurance.
• 401(k) with Rehlko matching.

About Rehlko

Rehlko proudly offers a rich history steeped in creativity and commitment to our associates and communities, along with competitive benefits and compensation. Our Purpose—Creating an energy resilient world for a better future—and Values: Curiosity, Trust, Pace, and Excellence, are important cultural components that shape the way we work and relate to one another. Learn more about Rehlko at www.rehlko.com/who-we-are.

EEO Statement

Rehlko is an equal opportunity/affirmative action employer. Our Values Curiosity – Seek, learn, share Trust – Go farther together Pace – Focus to go faster Excellence – Find the win every day