Location: Onsite at Kohler Energy, WI

Opportunity

KOHLER Power Systems is one of the largest power generator manufacturers in the world, has delivered energy solutions worldwide since 1920. KOHLER Power Systems offers power generation equipment for residential, industrial, mobile and marine applications as well as automatic transfer switches, switchgear, monitoring controls and accessories. For more information about KOHLER Power Systems, please visit www.kohlerpower.com.

As a Sr Project Engineer - Reliability, you will be responsible for driving aggressive preventive/corrective actions to improve reliability and reduce the Cost of Poor Quality. Ensuring our products meet the reliability and warranty targets is a key deliverable of this position. By analyzing reliability data, warranty data, and customer feedback, you will develop a list of priority projects. You will work with field service, design engineering, manufacturing quality, and supplier quality to validate your list and further prioritize the projects to resolve them. You will facilitate the problem-solving process by utilizing 8Ds or DMAIC projects to drive full closure and prevention. You will be responsible for reliability test planning, data collection, and data analysis to drive verification and validation. When a new product is released, you will be responsible for closely tracking and monitoring the field performance as part of an early warning tracking and reporting team. An expectation of this position is continuous improvement of the Problem Resolution process in conjunction with NPD.You will be a key member of the NPD process and responsible for the reliability test planning and closing of open incidents before product release.Work with multiple cross-functional groups to support NPD projects and have a positive impact on the reliability of newly released products to the market.

Specific Responsibilities

Structured Problem Solving

• Reduce internal and external failure costs due to design and process related failures.
• 8D facilitation, documentation, and training
• Use problem- solving tools and action plans to communicate and drive issue resolution.

Probability and Statistical Analysis

• Pareto and analyze warranty data to identify and communicate current issues.
• Six Sigma methodology to understand capability, failure rates, basic statistics.

Product Design and Development

• Review product reliability targets, set new targets, and test to confirm targets are met.
• Participate in and drive design reviews, including DFM/A, Serviceability, Routing, and Safety
• Work with engineering to develop product and component duty cycles to set design targets.

Measurement Systems & Analysis

• Data collection and instrumentation to be utilized to understand the physics of failure and system interactions.
• Develop test methods to simulate field environment.
• Drive and implement advanced test methods such as HALT, HASS, and ALT

Project Management

• Prioritize the field issues based on severity and cost to the business.
• Coordinate cross functional team internally and externally, to solve problems or facilitate strategic projects.
• New Product Development support, major issues, instrumentation, reliability test planning and support.

Quality Management System

• Review and present data and project status to upper management
• Participate in product gate reviews as needed.