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Senior Continuous Improvement Engineer

Generac · Whitewater, WI · Full time

Posted May 19, 2026 · We last checked this listing on Oct 6, 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.

About your past

Walk me through a kaizen event you led from start to finish. What was the problem, what did the team change, and what happened to the numbers afterward?

What they are checking: whether the candidate has actually run a full kaizen cycle and can speak to measurable, sustained results rather than just attending events

Tell me about a time you had to coach a plant floor team or a peer engineer who was resistant to changing how they worked. How did you get them on board?

What they are checking: coaching and influence skills, since this role is about mentoring others into lean thinking, not just doing the work solo

Give me an example of a root cause problem-solving effort where the obvious answer turned out to be wrong. How did you find the real cause?

What they are checking: rigor in problem solving methodology like 5 whys or fishbone versus jumping to conclusions

Tell me about a project where the team's KPIs improved for a while and then slid back to old habits. What did you learn from that?

What they are checking: understanding of sustainability of change, not just short-term event wins

Describe a time you had to lead a cross-functional team where people had very different skill levels or different priorities. How did you keep the project moving?

What they are checking: project leadership across diverse teams, which the posting flags as a preferred qualification

Tell me about a time you pushed back on a solution that leadership favored because you thought it challenged lean principles the wrong way.

What they are checking: willingness to challenge the norm and defend sound methodology, tied to the 'experiment and push boundaries' competency

What would you do

Say you're mapping a value stream and you find that the biggest source of waste is actually outside your facility, in how a supplier delivers parts. How do you handle that?

What they are checking: whether the person understands value stream mapping goes beyond four walls and knows how to escalate or collaborate cross-functionally

You're given three complex process problems across different areas of the plant and limited time. How do you decide which one to tackle first?

What they are checking: prioritization skill and whether they think in terms of impact and data rather than whoever is loudest

If you inherited a facility that has never used the Generac Manufacturing System or something like it, where would you start in the first ninety days?

What they are checking: ability to build a rollout strategy and sequence lean fundamentals like 5S and visual management before jumping to advanced tools

About the work

Describe how you'd set up standard work for a line that's never had it documented before. Who do you involve and in what order?

What they are checking: practical knowledge of standard work methodology and change management, not just textbook definitions

Tell me about a SMED project you've worked on. What was the changeover time before and after, and what specifically drove that reduction?

What they are checking: hands-on depth with SMED versus surface familiarity with the term

How would you use Kanban and plan for every part to fix a line that keeps running out of components at the worst times?

What they are checking: whether the candidate can actually apply PFEP and pull systems, since these were called out specifically as preferred experience

How do you decide which KPIs actually matter for a given process improvement, versus ones that just look good on a dashboard?

What they are checking: whether metrics are tied to real process control and customer or business impact, echoing the 'uses KPIs to create sustainable improvements' competency

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The full job description

As published by Generac.

We believe power is a promise - a shared commitment to be there for others when it matters most. For more than 65 years, we've turned big ideas into solutions that help protect homes, strengthen businesses and build a more resilient, efficient, sustainable energy future. Ready to Power a Smarter World with us? The Continuous Improvement Engineer III is responsible for leading the implementation of operational process improvements utilizing the Generac Manufacturing System (GMS) across the value stream in a manufacturing or distribution facility. The Continuous Improvement Engineer III provides hands on execution and coaching of the lean principles (Value Stream Mapping, Kaizen, 5S, Standard Work, Line/Cell Design, Single Piece Flow, Material Flow, Visual Management, SMED, TPM, Root Cause Problem Solving, etc.) and tools to eliminate waste in all operations functions. The Continuous Improvement Engineer III provides Continuous Improvement solutions to solve complex process issues. Essential Duties and Responsibilities: • Coach and lead the implementation of continuous improvement initiatives utilizing Lean principles (Value Stream Mapping, Kaizen, 5S, Standard Work, Line/Cell Design, Single Piece Flow, Material Flow, Visual Management, SMED, TPM, Root Cause Problem Solving, etc.) and the GMS. • Coach others to develop and implement Continuous Improvement solutions to solve complex process issues • Develop, document, and implement standard work to provide a basis of continuous improvement. • Mentor and guide facility team members and peers in the understanding, use and implementation of Lean principles and tools. • Participate in the implementation of standards and programs with the corporate Continuous Improvement team. • Participate in the implementation of facility strategic plans and initiatives. • Facilitate the flow of information sharing of best practices and external benchmarks. Minimum Qualifications: • Bachelor’s degree in engineering • 5 years of Continuous Improvement, Lean engineering experience Preferred Qualifications: • 5 years of demonstrated implementation experience in Lean principles • Lean, Operations or Supply Chain Certifications • Demonstrated experience in flow principles, Kanban, and plan for every part (PFEP) • Demonstrated experience in project leadership with a diversity of team skills Knowledge, Skills, Abilities: • Experiment and Push Boundaries – Designs/implements facility solutions that challenge the norm • Ideate & Breakthrough – Analyzes and implements successful facility change • Continuous Improvement – Uses KPI’s to create reliable/sustainable improvements, drives standard work, focuses on process • Drive to Win – Sets high performance standards, Monitors/redirects ensuring project results, Coaches balance, problem solving, improved customer/employee experience Great Reasons to work for Generac: • Competitive Benefits: Health, Dental, Vision, 401k and many more • Scheduled events throughout the year that allow our employees, both current and retirees, to gather together and enjoy their time with their families and co-workers • Pride! When a storm strikes, Generac employees always rise to the occasion. Each time a storm hits many employees volunteer their time with the customer support team or on the production line while others go right into storm-affected areas to repair generators • We believe in having fun. From minor celebrations to major events, our employees balance their work by building a strong culture of teamwork and collaboration through a variety of occasions, including our Fun Days. • Every day is Jeans Day! Dress for your day. • Product loan and discount programs Physical Demands: While performing the duties of this job, the employee is regularly required to talk and hear; and use hands to manipulate objects or controls. The employee is regularly required to stand and walk. On occasion the incumbent may be required to stoop, bend or reach above the shoulders. The employee must occasionally lift up to 25 - 50 pounds. Specific conditions of this job are typical of frequent and continuous computer-based work requiring periods of sitting, close vision and ability to adjust focus. “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.”

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