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Senior Continuous Improvement Engineer

Generac · Beaver Dam, WI · Full time

Posted Jun 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, and how did you know it worked after you left?

What they are checking: whether they can drive a lean event to a sustained result, not just a one-week activity

Tell me about a time you had to coach a production supervisor or team member who was resistant to changing their process. How did you handle it?

What they are checking: ability to lead through influence and coaching rather than authority, which is core to this role

Describe a standard work document you created that actually got used on the floor. What made it stick versus getting ignored?

What they are checking: experience translating lean theory into something operators actually adopt

Tell me about the most complex root cause problem you've solved. What tool did you use and how did you confirm the real root cause versus a symptom?

What they are checking: rigor in problem-solving methodology, not just running a fishbone for show

Tell me about a time you mentored a peer or junior engineer through their first lean project. What did you focus on teaching them?

What they are checking: coaching and mentoring capability, which the job weights heavily

Tell me about a time your improvement idea challenged how the plant had always done things and met real pushback from leadership. What happened?

What they are checking: ability to push boundaries and drive breakthrough change, matching the posting's stated values

What would you do

Say you're brought in to fix a line that's missing takt time. Where do you start, and what data do you pull first?

What they are checking: structured root cause thinking under a concrete manufacturing scenario

If two plant managers want conflicting things from a CI project you're leading, one wants speed, one wants full documentation, how do you handle that?

What they are checking: stakeholder management and prioritization skills under competing pressure

Imagine a work cell where 5S was implemented six months ago and has completely fallen apart. What's your plan to fix it for good this time?

What they are checking: understanding of what makes lean tools stick versus fade, and change management skill

About the work

How do you approach building a value stream map for a process you don't know well yet, and how do you decide where the biggest waste is hiding?

What they are checking: real hands-on VSM skill versus buzzword familiarity

What's your experience with SMED? Give me a specific changeover you improved and the before-and-after numbers.

What they are checking: concrete quantified experience versus general lean vocabulary

Have you worked with Kanban or Plan for Every Part? Tell me about a time you set one up and what problems it solved on the material flow side.

What they are checking: depth on the preferred-qualification skills that distinguish senior candidates

How do you use KPIs to prove an improvement is sustainable rather than a short-term bump?

What they are checking: understanding of sustaining gains, a stated priority in the posting

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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 Senior Continuous Improvement Engineer 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. Key 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. = 30% • Coach others to develop and implement Continuous Improvement solutions to solve complex process issues. = 20% • Develop, document, and implement standard work to provide a basis of continuous improvement. = 20% • Mentor and guide facility team members and peers in the understanding, use and implementation of Lean principles and tools. = 10% • 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: • Bachelors in Engineering, Mechanical, Quality, Supply Chain • 5 years of demonstrated implementation experience in Lean principles Preferred Qualifications: • 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 • 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 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 pounds. Specific conditions of this job include 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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