Senior Advanced Manufacturing Engineer - Process Optimization

Job description

We believe power is a promise - a shared commitment to be there for others when it matters most. For more than 65 years, we've turned big ideas into solutions that help protect homes, strengthen businesses and build a more resilient, efficient, sustainable energy future. Ready to Power a Smarter World with us? The Senior Industrial Engineer is the technical authority responsible for designing, optimizing, and transforming manufacturing systems for generator production and genset enclosing operations. This role drives strategic improvements across assembly, enclosure fabrication, fuel systems, cooling packages, wiring integration, and final packaged‑unit build. The engineer will architect world‑class manufacturing processes, deploy advanced automation, and lead cross‑functional initiatives that elevate throughput, quality, safety, and cost performance across the entire value stream. This position is ideal for a senior‑level engineer who blends deep industrial engineering expertise, systems engineering thinking, and hands‑on operational leadership Core Responsibilities 1. Manufacturing Systems Architecture Design and optimize end‑to‑end manufacturing systems for generator assembly and complete genset packaging (skids, enclosures, tanks, cooling systems). Develop long‑term capacity strategies, including equipment selection, automation roadmaps, and plant‑wide layout evolution. Build digital twins and simulation models(Arena, Flex SIM) to predict bottlenecks, labor requirements, and capital needs. Partner with Quality to reduce defects in generator assembly, wiring harnesses, and final assembly 2. Advanced Process Engineering Lead high‑precision process development for Assembly, Electrical Integration and Packaging Processes. Implement advanced industrial engineering tools: MTM, DOE, SPC, PFMEA, and process validation. Engineer fixtures, jigs, and tooling to improve repeatability and reduce ergonomic risk. 3. Lean Enterprise Leadership Drive enterprise‑level Lean transformation across generator manufacturing and packaging operations. Lead VSM events that span fabrication, assembly, testing, and logistics. Deploy SMED, 5S, Kanban, Heijunka, and standardized work at a systems level. 4. Automation & Technology Integration Identify and implement automation solutions such as Cobots, AGVs, and automated test systems. Collaborate with controls and IT teams to advance digital manufacturing maturity. 5. Cost Optimization & Value Engineering Lead cost‑out initiatives involving material usage, takt‑time reduction, design simplification, and supply chain alignment. Conduct make‑vs‑buy analysis for subassemblies and enclosure components Support DFM/DFA for new generator models and enclosure designs. 6. Cross‑Functional Leadership Serve as the technical bridge between Engineering, Operations, Supply Chain, Quality, and Facilities. Lead major capital projects, including new line installations, new plant setup, layout redesigns, and technology upgrades. Mentor junior engineers and develop the next generation of industrial engineering talent. Required Qualifications Bachelor’s degree in Engineering or Industrial Technology 5 years related experience in the Engineering function within a similar working environment. Preferred Qualifications Experience with generator manufacturing, genset packaging, or power systems integration. Knowledge of fuel systems, cooling packages, Engine Assembly, Fabrication and electrical testing. Familiarity with ERP/MRP systems (SAP). Experience in digital manufacturing, IIoT, or Industry 4.0 initiatives. Key Competencies Systems‑level thinking and strategic planning Strong analytical and problem‑solving capability Ability to influence at all organizational levels Exceptional communication and project‑management skills Hands‑on, shop‑floor‑driven leadership style Continuous‑improvement mindset with a bias for action 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. Great Reasons to work for Generac: Competitive Benefits: Health, Dental, Vision, 401k and many more Many employee activities Scheduled events throughout the year that allow our employees, both current and retirees, to gather together and enjoy their time with their families and co-workers Pride! When a storm strikes, Generac employees always rise to the occasion. Each time a storm hits many employees volunteer their time with the customer support team or on the production line while others go right into storm-affected areas to repair generators We believe in having fun. From minor celebrations to major events, our employees balance their work by building a strong culture of teamwork and collaboration through a variety of occasions, including our Fun Days. Every day is Jeans Day! Dress for your day. Product loan and discount programs “We are an equal opportunity employer and all qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, national origin, disability status, protected veteran status, or any other characteristic protected by law.”