Staff Mechanical QA Engineer

The Staff Mechanical Components Quality Engineer will serve as the critical technical liaison between engineering teams and manufacturing partners, ensuring scalable, high‑quality production of solar energy storage products. Location Ideally onsite in Waukesha, WI (alternate onsite locations: S. Portland, ME or Reno, NV). Major Responsibilities Work experience in mechanical components and assemblies design and development using CAD software such as SolidWorks and Creo. Strong understanding of 2D drawings and 3D CAD models, including application of proper tolerances and Geometric Dimensioning & Tolerancing (GD&T). Familiarity with aluminum molding/casting processes (e.g., die casting) and their design implications, including draft angles, wall thickness, and tooling constraints. Experience collaborating with tooling vendors and manufacturers to refine designs for production efficiency and quality. Align product quality targets with expected product performance and reliability requirements. Own overall product quality from a mechanical component’s perspective throughout the product lifecycle. Develop and execute comprehensive mechanical parts quality plans for new product introductions (NPI). Coordinate and conduct quality audits at Contract Manufacturers to ensure agreed inspection processes are followed and properly documented. Develop detailed Quality Requirement Specifications for high‑reliability products manufactured by external partners. Provide expert input on inspection methods, measurement instruments, and manufacturing process selections. Actively participate in Design Failure Mode and Effects Analysis (DFMEA) and Design for Manufacturability (DFM) activities. Lead and enforce Production Part Approval Process (PPAP) to ensure processes and tooling consistently meet quality standards. Lead Supplier Corrective Action Requests (SCAR) using the 8D methodology, ensuring timely and effective closure. Drive corrective and preventive actions (CAPA) related to manufacturing defects and material non‑conformances. Utilize Engineering Change Order (ECO) systems to manage and ensure effective implementation of design and process changes. Collaborate cross‑functionally with Design Engineering, Manufacturing Engineering, and Testing teams, including support for materials and process validation when required. Monitor compliance with applicable quality and safety certification standards. Interpret dimensional measurements and GD&T callouts from supplier’s First Article Inspection (FAI) and/or OQC reports, ensuring full compliance with customer engineering drawings. Demonstrate knowledge of manufacturing processes such as casting, molding, and stamping, and perform Critical‑to‑Quality (CTQ) analysis. Review mechanical drawings to identify gaps and ensure all necessary inspection requirements are clearly defined. Develop and maintain quality documentation, ensuring Contract Manufacturers (CMs) properly implement and retain records. Define, track, and continuously improve quality performance metrics. Source vendors, obtain quotations, and coordinate environmental and reliability testing as required. Collaborate with suppliers on part quality issues, including defect analysis and resolution. Familiarity with industry testing and certification standards (e.g., IPC, UL), including interpretation and application to product design, validation, and compliance requirements. Support cross‑functional quality initiatives and perform additional duties as assigned. Flexible work hours and night meetings to coordinate with offshore supply locations; up to 25‑30% travel, some international. Minimum Job Requirements Bachelor’s Degree in Mechanical Engineering. At least 7 years of experience in manufacturing high‑reliability electronic, electromechanical, or products with a focus on quality management in a contract manufacturing or electromechanical assembly environment. Strong experience with solder chemistries/processing, electronics cleaning and cleanliness validation processes, conformal coating, and potting. Solid quantitative skill set and the ability to analyze and communicate with well‑supported data. Knowledge of PCB design capability. Critical thinker capable of devising plans and solutions for complex problems. Preferred Job Requirements Power electronics, consumer electronics, or commercial electronics background preferred. Experience working with international companies and in a matrix organization. Proven experience collaborating with multiple sites and functions to drive common solutions. Prior experience with hardware certification standards (e.g., UL1741). Mechanical and thermal analysis experience. Familiarity with aluminum molding/casting processes (e.g., die casting) and their design implications. Experience collaborating with tooling vendors and manufacturers to refine designs for production efficiency and quality. Certification/License: familiarity with lean manufacturing principles; Six Sigma green or black belt preferred. Knowledge of PCB materials and manufacturing. 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. #J-18808-Ljbffr Generac Power Systems