JobsRegal Rexnord

Gear Manufacturing Engineer

Regal Rexnord · Milwaukee, WI

Posted Sep 16, 2026 · We last checked this listing on Sep 20, 2026

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Likely interview questions for this role

Written from this job description, not a generic list. Each one notes what the interviewer is really checking.

Behavioral

Describe a time you had a gear quality problem show up on the floor. How did you trace it back to root cause?

structured root cause analysis skill and whether they go beyond symptom-fixing

Tell me about a Lean or Six Sigma project you led on a manufacturing floor. What was the measurable result?

whether continuous improvement claims are backed by real projects with real numbers

Describe a situation where design engineering handed you a gear print that was difficult or impossible to manufacture efficiently. What did you do?

cross-functional collaboration skill and diplomacy when pushing back on design

Tell me about a time you had to balance a supplier's capability limits against a customer's tolerance requirements.

judgment in negotiating trade-offs between cost, capability, and spec compliance

Technical

Walk me through a gear manufacturing process you developed from scratch, starting with the part print and ending with a production-ready routing.

whether the candidate can own an end-to-end process development cycle, not just tweak existing setups

Tell me about the difference in process planning between cutting a cylindrical gear and a worm gear.

real hands-on familiarity with both gear types named in the posting, not just general machining knowledge

What experience do you have with gear hobbing, shaping, and grinding, and where does your depth run out?

honest self-assessment of hands-on breadth across the specific processes listed in the job

How do you use AGMA standards in your day-to-day process work?

whether they actually apply the standard or just recognize the acronym

What CAD/CAM software have you used for gear machining, and can you describe a specific program you wrote or modified for a CNC gear operation?

depth of CNC programming experience versus surface familiarity

How do you build a control plan for a new gear part, and what do you include to make sure it actually gets followed on the floor?

understanding of practical documentation that holds up in production, not just paperwork for audits

How comfortable are you with GD&T when reviewing gear prints, and can you give an example where a GD&T callout changed your process plan?

whether GD&T knowledge translates into actual manufacturing decisions

Have you worked within an ERP or SAP environment for routings and documentation? What role did it play in your daily work?

comfort with the administrative and systems side of the job, not just the technical floor work

Situational

If you saw a spike in tooth profile deviation on hobbed gears after a tool change, how would you go about isolating the cause?

practical troubleshooting logic specific to gear cutting operations, sequencing of checks before jumping to conclusions

A key customer calls with a technical complaint about gear noise or wear in the field. Walk me through how you'd handle that conversation and the investigation after it.

customer-facing technical communication and follow-through under pressure

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The full job description

As published by Regal Rexnord.

Work Model: This is a fully onsite role, with work performed at your designated Regal Rexnord office. ____________________ Position Overview: We are seeking a skilled and detail-oriented Gear Manufacturing Engineer to join our dynamic team. This role is responsible for developing, optimizing, and supporting manufacturing processes for gear production, ensuring high-quality output, efficiency, and compliance with engineering standards. Key Responsibilities: • Design and implement manufacturing processes for cylindrical and worm gear cutting, finishing, and assembly. • Collaborate with design engineers, quality engineers, and production teams to ensure manufacturability and cost-effectiveness. • Conduct root cause analysis and implement corrective actions for process-related issues. • Develop and maintain process documentation, including process drawings, routings, work instructions, and control plans. • Support continuous improvement initiatives using Lean and Six Sigma methodologies. • Interface with suppliers and customers on technical issues related to gear manufacturing. • Utilize CAD/CAM software and CNC programming for gear machining operations. • Ensure compliance with safety, quality, and environmental standards. Required Skills and Qualifications: • Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, or related field. • 4+ years of experience in manufacturing or precision machining. • Proficiency in manufacturing process development. • Experience with CNC machines, gear hobbing, shaping, and grinding. • Familiarity with ERP systems and manufacturing documentation. • Strong analytical, problem-solving, and communication skills. Preferred Skills and Qualifications: • Experience with AGMA standards and ISO 9001 quality systems. • Certification in Lean Manufacturing or Six Sigma is a plus. • Experience in gear manufacturing preferred. • Proficiency in gear design principles and GD&T preferred. • Experience with SAP preferred. Restrictions imposed by federal export control laws may limit this job opportunity to candidates who are a ‘U.S. Person’, which includes U.S. citizens, U.S. nationals, U.S. permanent residents, individuals granted asylum in the United States, and refugees in the United States.   Candidates must be eligible to work in the United States without requiring company sponsorship to obtain or keep U.S. work authorization. Benefits • Medical, Dental, Vision and Prescription Drug Coverage • Spending accounts (HSA, Health Care FSA and Dependent Care FSA) • Paid Time Off and Holidays • 401k Retirement Plan with Matching Employer Contributions • Life and Accidental Death & Dismemberment (AD&D) Insurance • Paid Leaves • Tuition Assistance About Regal Rexnord Regal Rexnord is a publicly held global industrial manufacturer with 30,000 associates around the world who help create a better tomorrow by providing sustainable solutions that power, transmit and control motion. The Company’s electric motors and air moving subsystems provide the power to create motion. A portfolio of highly engineered power transmission components and subsystems efficiently transmits motion to power industrial applications. The Company’s automation offering, comprised of controls, actuators, drives, and precision motors, controls motion in applications ranging from factory automation to precision control in surgical tools. The Company’s end markets benefit from meaningful secular demand tailwinds, and include factory automation, food & beverage, aerospace, medical, data center, warehouse, alternative energy, residential and commercial buildings, general industrial, construction, metals and mining, and agriculture. Regal Rexnord is comprised of three operating segments: Industrial Powertrain Solutions, Power Efficiency Solutions, and Automation & Motion Control. Regal Rexnord has offices and manufacturing, sales and service facilities worldwide. For more information, including a copy of our Sustainability Report, visit RegalRexnord.com. Equal Employment Opportunity Statement Regal Rexnord is an Equal Opportunity and Affirmative Action Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex/gender, sexual orientation, gender identity, pregnancy, age, ancestry, national origin, genetic information, marital status, citizenship status (unless required by the applicable law or government contract), disability or protected veteran status or any other status or characteristic protected by law. Regal Rexnord is committed to a diverse and inclusive workforce. We are committed to building a team that represents diverse and inclusive backgrounds, perspectives, and skills.  If you’d like to view a copy of the company’s affirmative action plan for protected veterans/individuals with disabilities or policy statement, please email Recruiting@RegalRexnord.com. If you have a disability and you believe you need a reasonable accommodation in order to search for a job opening or to submit an online application, please e-mail Recruiting@RegalRexnord.com. Equal Employment Opportunity Posters Notification to Agencies : Please note that Regal Rexnord Corporation and its affiliates and subsidiaries ("Regal Rexnord") do not accept unsolicited resumes or calls from third-party recruiters or employment agencies. In the absence of a signed Master Service Agreement or similar contract and approval from HR to submit resumes for a specific requisition, Regal Rexnord will not consider or approve payment to any third-parties for hires made.

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