Senior Project Engineer - Manufacturing

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We have met today's energy needs while planning for tomorrow's for over 100 years. Beginning with the first modern generator, the Rehlko Automatic Power & Light, launched in 1920, Rehlko has been an innovative leader in energy resilience. Our product range includes engines, generators, power conversion, UPS systems, EV components and electrification solutions, microgrid controls and management, clean energy solutions, and much more that serve a broad spectrum of OEM, residential, industrial, and commercial customers.

Our priorities are global: the stability from steady energy sources and reliable back‑ups, the power to harness energy, and the freedom of not being dependent on an aging centralized grid. The confidence that clean energy solutions offer when it comes to a sustainable world, and the commitment to keep innovating towards greater impact. 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!

Under the direction of the Manager, Manufacturing Engineering, the Sr Project Engineer - Manufacturing will be responsible for safety, quality, on‑time delivery, cost reductions, productivity, and continuous improvement in their assigned areas. Primary responsibilities will include meeting performance goals, maintaining quality expectations, and improving the three M’s (Mura, Muda, and Muri). Provide mentorship to manufacturing technicians and production staff. Design, develop, and implement manufacturing processes, systems, and equipment for new and existing products.

Work closely with design engineering on new, existing, and changing products to provide a smooth transition from design to production.

• Work on a team responsible for keeping production flowing, meeting performance goals, and maintaining Rehlko’s high level of quality.
• Analyze present manufacturing operations and implement improvements to methods, equipment, and layouts that streamline operations, improve safety, quality, and reduce costs.
• Develop and implement cost savings projects and serve as a coach/mentor for structured problem solving (DMAIC, PDCA, 8D/PSP, 4Q, or A3).
• Interface and effectively participate in the design process with a DFA, DFM, DFX mindset.
• Coordinate new product introductions to production, and work closely with Design Engineering, Marketing, and the production floor to ensure successful implementation.
• Establish and maintain shop floor routings for all products and engineering specials.
• Conduct feasibility studies to estimate product cost and analyze capital equipment, capacity, and capability requirements.
• Plan, design, document, improve, and control the optimal processes used to manufacture products.
• Evaluate and challenge designs for technical merit, working closely with the engineering and design teams to realize optimal outcomes.
• Work collaboratively with production, supervisors, production planning/scheduling, purchasing, design engineering, quality, materials, and accounting to drive improvements throughout the facility.
• Manage capital improvement projects throughout assigned areas; serve as the project manager directing the work of a multi‑disciplined team.
• Maximize efficiency/throughput by analyzing layout of equipment, workflow, assembly methods, and workforce utilization.
• Lead continuous improvement projects by focusing on productivity improvements and cost reduction efforts to constantly improve the process and lower operating costs.
• Improve and optimize material flow and sequence of operations to assure full utilization of resources and equipment.
• Foster an environment that encourages creativity, risk‑taking, inclusive collaboration, and timely…