Senior Project Engineer of Reliability & Customer Quality

Our work is guided by our purpose: creating an energy-resilient world for a better future. This purpose embodies the legacy we bring, with more than 100 years as the global leader in energy resilience, delivering solutions critical to sustain and improve life.

Our teams have the opportunity to provide a critical resource – energy – that ensures safety, security, and independence for people around the world. Our team members are focused on pushing boundaries, continuing to innovate in an ever-changing landscape, and keeping up with the pace required to create solutions for today’s world demands.

Our product range includes engines, generators, power conversion, UPS systems, EV components and electrification solutions, microgrid controls and management, and clean energy solutions that serve a broad spectrum of OEM, residential, industrial, and commercial customers. At Rehlko, you have the freedom to identify, create, and deliver solutions – large and small – that help people and communities thrive in the moments that matter.

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!

What We Offer

At Rehlko, our Total Rewards programs are designed to accelerate growth, energize performance, and support a culture of inclusion at every stage of life and work. We offer total rewards that are easily understood, recognize results, enable career mobility, and reflect our commitment to valuing diverse needs in a fast-moving world. We provide:

• Competitive compensation and benefits

• Work-life flexibility

• Recognition and rewards

• Development and career opportunities

• A safe and inclusive workplace

Why You Will Love this Job

The Senior Project Engineer of Reliability & Customer Quality to serve as a support technical leader focused on improving product reliability, enhancing customer experience, and driving warranty performance across both existing products and New Product Development (NPD).

This role combines deep technical expertise with strategic influence, leading complex problem-solving initiatives, mentoring engineering talent, and partnering cross-functionally to proactively identify and mitigate reliability risks. You will play a critical role in assisting with reducing the Cost of Poor Quality (COPQ), ensuring successful product launches, and driving continuous improvement across the organization.

This opportunity is ideal for an experienced engineer who thrives in a high-impact role, enjoys solving complex challenges, and can influence outcomes across teams without direct authority.

• Work mode: Onsite-Monday-Friday
• Location: N7650 County Rd LS, Sheboygan, WI, 53083
• Relocation assistance available

Key Responsibilities

Reliability Engineering & Customer Quality Leadership

• Co-lead high-impact reliability improvement initiatives addressing field, warranty, and customer issues
• Serve as a key contributor within the NPD process, ensuring reliability requirements are defined, validated, and achieved prior to product release
• Partner with Product Development teams to identify Critical-to-Quality (CTQ) characteristics and develop robust validation plans
• Drive reliability growth strategies, including risk identification and mitigation for new technologies and designs
• Act as a support technical escalation point for complex reliability and customer quality concerns
• Monitor early field performance of new products and lead containment and corrective actions as needed

Structured Problem Solving

• Co-lead and facilitate advanced problem-solving efforts using methodologies such as 8D, DMAIC, and 5-Whys
• Drive reduction of internal and external failure costs through root cause analysis and sustainable corrective actions
• Ensure disciplined execution of preventive and corrective measures across design, manufacturing, and supplier-related issues

Data Analysis & Reliability Methods

• Analyze warranty, field, and test data to identify trends, prioritize actions, and quantify business impact
• Apply statistical tools such as Pareto analysis, Weibull analysis, and reliability modeling
• Support development of reliability targets, warranty projections, and product validation readiness

Product Development & Design Support

• Influence design reviews, including DFMEA, robustness, serviceability, and safety considerations
• Develop and execute reliability test plans aligned with real-world operating conditions and risk profiles
• Ensure closure of all reliability and customer quality issues prior to production release

Continuous Improvement & Standardization

• Drive enhancements to reliability engineering processes, tools, and standard work
• Support development and deployment of best practices and standard operating procedures
• Act as a champion for quality and continuous improvement across the organization

Requirements:

• Bachelor’s degree in Engineering (Mechanical, Electrical, Manufacturing, or related) from an ABET-accredited institution
• 5-7 years of experience in Reliability, Quality, Design, or Manufacturing Engineering
• 2–5 years of direct experience in reliability or customer quality within industrial, automotive, engine, generator, or heavy equipment environments

Technical Expertise preferred:

• knowledge of structured problem-solving methodologies (8D, DMAIC, 5-Whys)
• Experience with reliability engineering principles, test planning, and data analysis
• Background in warranty analysis and field failure investigation

Additional Skills:

• Strong communication and presentation skills, with the ability to influence stakeholders at all levels
• Proficiency with Microsoft Office tools (Excel, PowerPoint, Power BI)

About Us

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 http://www.rehlko.com/who-we-are.

In addition to the investment in your development, Rehlko offers a benefits package including a competitive salary, health, vision, dental, 401(k) with Rehlko matching, and more!?

Rehlko is an equal opportunity employer that prohibits discrimination and will make decisions regarding employment opportunities, including, but not limited to, hiring, job assignment, compensation, promotion, benefits, training, discipline, and termination, without regard to race, creed, color, ethnicity, religion, sex, pregnancy, childbirth, or related medical conditions, genetic information, age, national origin, citizenship, ancestry, caste, mental or physical disability, marital or familial status, sexual orientation, gender identity or expression, genetic information, political belief or affiliation, union membership status, military status, veteran status, or any other characteristic protected by national, state, local, or other applicable laws.

Americans with Disabilities Act (ADA)

 It is the policy of Rehlko to comply with all applicable provisions of the Americans with Disabilities Act (ADA) and corresponding national, state, local, or other applicable laws. Rehlko will not discriminate against any qualified associate or applicant with respect to any terms, privileges, or conditions of employment because of a person's physical or mental disability. Rehlko will provide a reasonable accommodation to associates or applicants with disabilities, in accordance with applicable laws. If you have a disability and require an accommodation in the application process or during the course of employment, please contact [email protected]. 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