Staff Reliability Engineer – Customer Quality

Why Work at Rehlko 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 Staff Engineer of Reliability & Customer Quality to serve as a 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 reducing 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 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 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 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 Cross-Functional Leadership Lead cross-functional teams across Engineering, Manufacturing, Supplier Quality, Field Service, and Operations Manage multiple concurrent initiatives of moderate to high complexity Mentor and coach engineers, strengthening organizational capability in reliability and quality engineering 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 7–10 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: Strong knowledge of structured problem-solving m