We are Generac, a leading energy technology company committed to powering a smarter world.

Over the 60 plus years of Generac’s history, we’ve been dedicated to energy innovation. From creating the home standby generator market category, to our current evolution into an energy technology solutions company, we continue to push new boundaries.

Generac Clean Energy combines the speed and excitement of a technology startup with the resources and market power of an S&P 500 industry leader. Our careers offer boundless opportunity for energetic, mission-driven applicants who seek challenge and impact in a fast-paced culture of teaching, learning, and professional growth, developing solar & storage products and software for the clean energy revolution.  

Join Generac Clean Energy as we drive to build energy solutions for a more resilient, sustainable world.

Summary:

Generac Clean Energy Solutions is looking for a highly motivated Staff Process Engineer to serve as the on-site technical leader for Generac’s cutting-edge Power Electronics products. You will be working cross functionally with product design, Test, Quality Engineering, and supply chain to solve challenges, improve manufacturability, and implement continuous improvement projects to improve yield and drive cost reduction. This position requires fostering close collaboration with the contract manufacturer’s operations and engineering teams. As a member of the Manufacturing Engineering organization, you will also work closely with manufacturing and quality engineers to launch new equipment and lines, and to evaluate data and process controls, determining process limits to align output targets with Best-in-class manufacturing quality.

Roles and Responsibilities:

Lead cross-functional teams in the development of Process Flows, Control Plans, GR&R, Manufacturing Instructions, Process capability, Rework Procedures, Calibration and Qualification of tools, Quality Validation, Risk Assessments (PFMEA) & New product introduction procedures. Analyze, develop, process, and implement improvements via Engineering Change Control. 

Collaborate with Manufacturing Engineers and Automation integrators to commission and launch new automated manufacturing equipment. 

Refine and launch Manual or Semi-auto operations with EHS and MFG ENG, contributing to the identification, prevention, and mitigation of safety hazards, proposing and implementing engineering solutions and controls

Develop expertise in assembly processes, and quantify process capabilities through critical data analysis and in-depth understanding of the product requirements

Improve line and process operations, including material flow, waste reduction, and ergonomics, utilizing Lean Manufacturing best practices.

Participate in the transition of a product from pilot line production into mass manufacturing, developing documentation to sustain robust systems and quality standards

Drive continuous improvement projects to maximize yield, capacity, and capability

Lead engineering teams to execute complex projects while maintaining clear communication channels and detailed reporting to senior management

Lead cross functional collaboration efforts in the identification, improvement, and mitigation of KPI indicator such as scrap and product cost

Analyze data from various sources to identify process quality and efficiency trends. Develop robust and clear data collection, visualization, and analysis tools. Enable data-driven operational and financial decisions through predictive insights into tool and process performance, including integration of factory data systems and use of software such as MySQL, Python, R, JMP, Minitab, Tableau, and Ignition

Monitor and reduce process variation using techniques such as Statistical Process Control (SPC) and Measurement Systems Analysis (MSA) techniques. Monitor and audit manufacturing processes to ensure product specifications and standards are met.

Launch and sustain MES (Manufacturing Execution Systems) and Process Flow updates to enhance traceability and OEE performance.

Minimum Qualifications:

7+ years working on processes within high volume automation production systems; strong background in semi-auto operations and manual poke-yoke controls a plus

Degree in Engineering

Good understanding of Bill of Materials, Manufacturing Execution System, Specification Management, Change Point Management

Data collection and analysis experience. Ability to develop data driven root cause analyses and solutions

Strong problem-solving skills and an aptitude for learning systems quickly.  Able to utilize structured problem-solving techniques such as DMAIC, Ishikawa, Five Why (5W) or Eight Disciplines (8D). Able to resolve high level performance issues into addressable actions

Exceptional capacity for managing simultaneous activities, competing priorities and challenges. Strong ability to work and communicate effectively with team and within an engineering organization. This includes excellent written and verbal communication skills

Creative capacity to develop innovative methods of scaling assembly systems at lower cost, on shorter timelines, or both

Travel required ~ 10%

Preferred Qualifications:

5+ years of experience in manufacturing roles for PCBA, Electronics, or Battery AssemblyDemonstrated breadth and/or depth in Assembly processes, including precision dispense, electrical tests, transducerized fastening, leak testing, and vision inspection.Design / Specification experience with automatic conveyance and robotic systems (FANUC preferred)

Physical Demands: While performing the duties of this job, the employee is regularly required to talk and hear; and use hands to manipulate objects or controls. The employee is regularly required to stand and walk.  On occasion the incumbent may be required to stoop, bend or reach above the shoulders. The employee must occasionally lift up to 25 - 50 pounds. Specific conditions of this job are typical of frequent and continuous computer-based work requiring periods of sitting, close vision and ability to adjust focus. Occasional travel.

“We are an equal opportunity employer and all qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability status, protected veteran status, or any other characteristic protected by law.”