Staff Engineer-Testing

Staff Engineer - Testing

The Staff Engineer - Testing will serve as the lab's technical authority for NVH and structural dynamics across engines, engine components, sub-assemblies and engine powered applications. Own the test strategy, standard work, and data quality for acoustic/vibration performance, fatigue/materials, and fastener/joint integrity. Provide day-to-day technical direction to technicians and analysts as an individual contributor. Develop and maintain the capability roadmap and methods spanning electrodynamic shakers, servo-hydraulic systems, strain gage instrumentation, vibration and acoustic.

This role will begin onsite in Kohler, WI, with the potential to transition to a hybrid schedule after six months.

Specific Responsibilities:

• Translate program targets and DFMEA risks into clear test plans, acceptance criteria, and instrumentation strategies.
• Develop and maintain standard test methods, work instructions, and data-quality criteria.
• Define fixture design guidelines and instrumentation best practices.

• Provide day-to-day technical direction to Engineering Technicians and Analysts.
• Lead cross-training across all test domains.
• Assist in test set-up and data acquisition for complex cases
• Provide design guidance to program teams.

• Create test plans; guide fixture conceptualization; oversee complex investigations.
• Perform analysis of vibration/strain/force/acoustic data and produce recommendations.
• Fastener/joint integrity: bolt stretch/elongation (including ultrasonic or torque methodologies), gasket sealing (Fuji film), and joint analysis.
• Materials/fatigue and tensile testing, including use of environmental chambers as required.
• Plan and direct shaker-based durability and NVH tests: swept sine, random, field data replication, resonance identification and dwell.
• Deliver clear engineering reports and presentation of those reports as needed.

• Support prioritization and throughput; drive uptime via proactive PMs and continuous improvement of methods, fixtures, and data management.
• Oversee calibration/verification for all sensors and DAQ channels.
• Champion capital planning for future testing capabilities
• Implement method/fixture/data improvements.

• Collaborate with Rehlko Analytical Engineering Group to support and validate CAE simulation
• Work with outside vendors/consultants for simulations and tests not available in-house; assess feasibility to bring capabilities in-house.
• Provide clear recommendations to program teams and management; influence design decisions with sound engineering evidence.
• Evaluate and apply simulation work and acquisition tools (e.g., Simcenter Testlab/3D Acoustics, Vibration View, MTS Multipurpose Elite

Requirements:

• BS in Mechanical/Aerospace/Acoustics/Vibration or related field; MS preferred.
• 5+ years in NVH, structural dynamics, vibration/fatigue/materials, or fastener/joint integrity, including high-speed data acquisition and advanced signal processing.
• Hands-on expertise with electrodynamic shakers, servo-hydraulic systems, strain gage application, vibration and acoustic data acquisition, and specialized bench tests.
• Technical leadership without formal authority; mentoring capability.
• Proficiency in signal processing (time/frequency/crank angle domain analysis, PSD/FFT/FRF autospectra/cross spectra/spectrum, filtering, aliasing, sound quality equalization, integration differentiation).
• Familiarity with Simcenter Testlab/3D Acoustics, Vibration Research controllers, and common DAQ platforms.
• Strong communication, troubleshooting, and ability to balance multiple programs.
• You will be working in an office/lab environment with exposure to engines and vibration equipment.
• Occasional lifting up to ~35 lb.; limited travel (<10%).

Applicants must be authorized to work in the US without requiring sponsorship now or in the future.

The Salary range for this position is $98,900.00-$125,600.00.The specific Salary rate offered to a candidate may be influenced by a variety of factors including the candidate's experience, their education, and the work location.