JobsGenerac

Sr. Advanced Manufacturing Engineer - Wire Harnesses

Generac · Waukesha, WI

Posted Jul 30, 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 project where you owned execution from engineering into full production. Where did it almost fall apart and what did you do?

end-to-end project ownership and resilience under real manufacturing pressure

Tell me about a time you had to directly supervise technicians or lab personnel through a difficult ramp-up. How did you handle pushback or performance issues?

actual people-leadership experience with shop-floor staff, not just cross-functional coordination

Tell me about a time you improved build efficiency or reduced cycle time on a harness assembly line. What did you measure and what actually moved the needle?

genuine continuous improvement track record versus generic lean vocabulary

Tell me about a time engineering and operations disagreed on a design or process change. How did you get alignment?

communication skill and credibility bridging the engineering-to-manufacturing gap this role is built around

Tell me about a quality escape or defect that made it to production. What was the root cause and how did you prevent recurrence?

ownership and rigor around quality systems rather than blame-shifting

Technical

Walk me through a wire harness you designed from concept through industrialization. What were the key architecture decisions around connectors, routing, and shielding?

whether the candidate has real end-to-end harness design experience, not just component-level knowledge

Tell me about a time you led a design through DFMEA and PFMEA. What failure modes surprised you and how did the control plan change as a result?

depth of hands-on FMEA and validation experience versus box-checking familiarity

Which of these tools have you actually used day to day: CATIA, NX, Creo, Capital, or Zuken E3, and what did you build with them?

real tool fluency versus resume keyword matching

Have you worked with high-voltage or complex electrical systems? Tell me about a specific safety or protection challenge you solved.

real exposure to high-voltage complexity given the preferred qualifications, especially relevant if EV work is involved

If you had to move from low-volume prototype builds to high-volume production for a harness design, what would you change first and why?

understanding of design-for-manufacturing tradeoffs at scale, not just theoretical knowledge

Situational

A supplier delivers connectors that are slightly out of spec three days before a validation build. Walk me through what you'd do.

practical crisis management and how they balance schedule pressure against quality risk

You're brought in on an NPI program that's already behind schedule and the line layout is fighting the harness routing. How do you diagnose the problem and fix it?

ability to integrate engineering design decisions with real manufacturing line constraints

What program management approach or tools do you rely on to keep cross-functional teams on track, and where have they broken down for you?

whether stated PM experience or PMP-equivalent skills hold up under real complexity

Practice this interview out loud.

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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? We are seeking a results-driven Senior Wire Harness Engineer with strong project management and manufacturing leadership experience to support advanced manufacturing operations. This role is responsible for designing robust wire harness solutions while driving seamless execution from engineering through production, including direct leadership of technicians and close engagement with the manufacturing floor. Key Responsibilities: • Advanced Manufacturing & Engineering Execution • Lead the design, development, and industrialization of wire harness systems for production environments. • Project & Program Management • Own end-to-end project execution across engineering and manufacturing phases. • Team Leadership (Technicians & Shop-Floor Support) • Provide direct supervision to harness technicians and lab/build personnel. • Manufacturing Integration & Operational Excellence • Partner closely with production teams to optimize line layout, tooling, and build efficiency. • Technical Expertise • Define harness architecture including connectors, terminals, routing, shielding, and protection systems and necessary fixtures/tool for high volume production. • Lead FMEA (DFMEA/PFMEA), control plans, and validation activities. • Use tools such as CATIA, NX, Creo, Capital, or Zuken E3, and PLM systems. Required Qualifications: • Bachelor’s degree in Engineering or Industrial Technology • 5 years related experience in the Engineering function within a similar working environment.  Preferred Qualifications: • Proven experience supporting production, NPI, and manufacturing ramp-ups • Experience leading technicians or shop-floor teams • Strong understanding of manufacturing processes, assembly methods, and quality systems • Demonstrated project management experience with cross-functional teams • Experience in advanced manufacturing, EV, industrial equipment, or high-mix/low-volume production • PMP certification or equivalent program management experience • Lean / Six Sigma (Green Belt or higher) • Familiarity with automation, digital manufacturing tools, or Industry 4.0 practices • Experience with high-voltage or complex electrical systems Key Competencies: • Strong engineering-to-manufacturing integration mindset • Hands-on leadership with shop-floor presence • Execution focus with high accountability • Continuous improvement and Lean thinking • Ability to balance technical depth with operational speed • Strong communication across engineering and operations Work Environment: Predominantly on-site in manufacturing and engineering environments. High interaction with production floor, labs, and cross-functional teams. Occasional travel to suppliers, validation sites & Production Sites Great Reasons to work for Generac:  • Competitive Benefits: Health, Dental, Vision, 401k and many more • State-of-the-art facility with an onsite gym, walking trails, café, free parking and many employee activities  • 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 • Eligible for summer hours! (Memorial Day – Labor Day) • 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 “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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