JobsGenerac

Senior Staff Controls Engineer

Generac · Sussex, WI

Posted Sep 7, 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

Tell me about a time your model-based design and simulation work did not match real-world behavior once you got to hardware. What did you do?

how they handle the gap between simulation fidelity and physical reality, a core risk in this role

You mentioned sitting on a regulatory committee. What was the technical issue you were weighing in on, and how did your input change the outcome?

genuine standards-body experience versus a resume line, and ability to influence outside their own company

Describe a time you mentored a less experienced engineer through a technical problem they were stuck on.

whether they can teach and transfer judgment, since this role is expected to coach juniors

Tell me about a project where you had to translate a complex controls issue for a non-technical audience, like finance or sales leadership.

communication skill across audiences, which the posting explicitly calls out

Tell me about a time you led a small cross-functional team toward a milestone when the team didn't report to you directly.

informal leadership and influence, since the role may lead teams without formal authority

Technical

Walk me through a closed loop control system you designed from scratch, including how you tuned it and how you verified stability.

whether the candidate has hands-on depth in control theory versus surface familiarity

How do you approach auto code generation from a simulation model to get it production-ready? What checks do you build in before that code goes on real hardware?

practical rigor around a specific, named workflow rather than just theoretical knowledge

Describe a test and validation plan you built that used HIL or SIL testing along with fault injection. What faults did you choose to inject and why?

depth of experience designing validation coverage, not just running pre-built test scripts

How have you used SAP or a similar ERP system in your engineering work, like managing bills of materials or part specifications?

practical familiarity with the administrative backbone of new product development, not just design work

What's an engineering standard or procedure you've written or significantly revised, and why did it need to change?

whether they operate at the level of setting institutional practice, not just following it

Situational

Tell me about a design you had to defend when a manufacturing partner pushed back on cost or manufacturability.

how they balance engineering ownership with cross-functional compromise

A new product's controls are behaving unpredictably under a specific load condition two weeks before a scheduled release. Walk me through how you would triage that.

structured problem-solving under time pressure on something safety- and schedule-critical

This job is roughly 80 percent travel and field-based. Tell me about a time you had to solve a hard engineering problem on-site, away from your usual tools and team.

comfort and competence working independently in the field, which is central to how this role actually operates

Describe a risk analysis you did on a product design where safety and cost were in tension. How did you make the call?

judgment on trading off safety, reliability, and cost, which the posting lists as explicit design evaluation criteria

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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 Staff Controls Engineer role is field-based and is responsible for providing expertise regarding new product development as well as continuous improvement of legacy systems.  Day to day responsibilities include control design and tuning, simulation development, PLC programming, and electrical system integration. The role interfaces with the cross functional teams across the organization to facilitate product development through design, validation, and release.  Major Responsibilities: • Designs, validates, and brings new products to market.  • Specifies precise new product functional requirements; designs, tests and integrates complex components to produce final designs; and evaluates the design's overall effectiveness, cost (including cost/benefit analysis), reliability (risk analysis), and safety.  • Designs, develops, executes and evaluates fitness-for-use testing, product specifications and process validation plans for a variety of complex products and/or components; creates and reviews material part specifications and bills of materials.  • Collaborates with internal manufacturing partners, contract manufacturers, designers and product specialists to optimize complex and advanced designs for manufacturability.  • Supporting product development plans (schedule, product cost, meeting design inputs) • Acts as a resource to mentor and teach less experienced engineers • 80% travel required. • Other duties as assigned. Minimum Job Requirements: • Bachelor of Science Degree in Electrical Engineering or Mechanical or related discipline. • 10+ years of relevant work experience; Knowledge / Skills / Abilities • Ability to perform detail-oriented work with a high degree of accuracy on multiple, complex projects, • Proven expertise in developing control algorithms across diverse power control and power management applications. • Expertise in closed loop control tuning, stability analysis, and performance optimization of advanced control algorithms. • Expertise in model-based design methodologies, including development of high-fidelity system simulations, automated design verification and production-ready auto code generation. • Experience in test & validation plan and procedure development and execution including multiple methods (HIL/SIL, bench component and/or system testing, fault injection methods, etc.); • Experience sitting on a regulatory committee in a technical role. • Strong written communication and presentation skills. • Ability to translate technical information to all audiences. • Applies engineering knowledge and experience to improve products, services and processes. • MS Excel, MS Word. • Experience with machine design. • Previous experience using SAP or equivalent ERP. Preferred Job Requirements • Master’s degree in electrical or mechanical engineering with focus on control engineering. Knowledge / Skills / Abilities • Works independently, with guidance in only the most complex technical issues • Requires specialized in-depth knowledge and/or breadth of expertise. • Interprets internal or external business issues and recommends solutions / best practices, strong business acumen • Solves complex problems • Takes a broad perspective to identify solutions • Strong decision-making skills • May lead small- to medium-sized cross-functional technology development teams to achieve milestones and objectives. • Ensure success cross-functionally.                                                                                                                  • Coaches and mentors less experienced engineers.                                                    • Offer recommendations and implement solutions. • Take ownership of designs • Is recognized as an expert in own area within the organization. • Writes standards and procedures • Leading efforts to improve the financial impact of engineering and related cross-functions on the business • Excellent conceptualization, visualization, and creativity • Excellent time management, prioritization, and analytical problem solving        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 pounds. Specific conditions of this job are typical of frequent and continuous computer-based work requiring periods of sitting, close vision, and the ability to adjust focus. Up to 80% travel and valid Driver’s License required.               “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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