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Staff Engineer - Residential New Product Development

Rehlko · Kohler, WI · $113,000–$143,950 a year · Full time

Posted Jul 8, 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 new product you helped take from concept to launch. What was your part in it?

What they are checking: Whether they have led real development work through gates and launch, not just supported one phase of it.

Tell me about a time you had to make a tradeoff between cost and performance on a product. How did you decide?

What they are checking: Whether they weigh tradeoffs with data and clear reasoning, which residential pricing pressure demands constantly.

As a staff engineer you guide others without managing them. How have you raised the quality of a team's engineering work?

What they are checking: Whether they lead through design reviews and mentoring, which is what separates a staff engineer from a strong individual contributor.

Tell me about a time you disagreed with marketing or product management on a feature. How did it end?

What they are checking: Whether they can push back with evidence and still keep a working relationship with the commercial side.

How do you keep up with changes in residential energy, like batteries, solar or smart home controls?

What they are checking: Whether they are curious about where home energy products are going, which shapes the next generation of designs.

What would you do

Your team is behind schedule and a test shows a failure two months before launch. What do you do?

What they are checking: Whether they protect product quality and raise the issue honestly instead of rationalizing a risky launch.

About the work

A home standby generator sits outside in every kind of weather. What design requirements does that drive for you?

What they are checking: Whether they think through corrosion, temperature, noise and installation realities that residential products face for years.

How do you turn what homeowners and installers want into engineering requirements you can test against?

What they are checking: Whether they can translate voice of the customer into measurable specs instead of vague feature wishes.

How would you plan validation testing for a new residential generator before launch?

What they are checking: Whether they know how to build a test plan that finds failures early, covering durability, emissions, noise and safety.

How do you work with manufacturing so a new design is easy to build in volume?

What they are checking: Whether they apply design for manufacturing early instead of handing an unbuildable design over the wall.

Residential products have to meet safety and emissions rules. How have you managed certification on a past product?

What they are checking: Whether they plan for agency testing and compliance as part of the schedule, not a surprise at the end.

Practice this interview out loud.

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The full job description

As published by Rehlko.

Why Work at Rehlko Our work is guided by our purpose: creating an energy-resilient world for a better future. This purpose embodies the legacy we bring, with more than 100 years as the global leader in energy resilience, delivering solutions critical to sustain and improve life. Our teams have the opportunity to provide a critical resource – energy – that ensures safety, security, and independence for people around the world. Our team members are focused on pushing boundaries, continuing to innovate in an ever-changing landscape, and keeping up with the pace required to create solutions for today’s world demands. Our product range includes engines, generators, power conversion, UPS systems, EV components and electrification solutions, microgrid controls and management, and clean energy solutions that serve a broad spectrum of OEM, residential, industrial, and commercial customers. At Rehlko, you have the freedom to identify, create, and deliver solutions – large and small – that help people and communities thrive in the moments that matter. At Rehlko, our team members are the essential energy that powers our organization’s success. We are committed to fostering a safe and sustainable work environment where safety is everyone’s responsibility. We empower every team member to actively participate in our Zero Is Possible safety culture by encouraging open communication, proactively reporting hazards, following protocols, and suggesting improvements. Join us in creating an energy resilient world for a better future! What We Offer At Rehlko, our Total Rewards programs are designed to accelerate growth, energize performance, and support a culture of inclusion at every stage of life and work. We offer total rewards that are easily understood, recognize results, enable career mobility, and reflect our commitment to valuing diverse needs in a fast-moving world. We provide: • Competitive compensation and benefits • Work-life flexibility • Recognition and rewards • Development and career opportunities • A safe and inclusive workplace Why You Will Love this Job Under the direction of the Sr. Manager, NPD Engineering, the Staff Engineer – Residential New Product Development will support the development of innovative products, including Automatic Transfer Switches and both air‑cooled and liquid‑cooled generators. The role provides technical direction and project leadership in the development of power generation solutions, while coordinating and guiding the efforts of CAD Design Analysts, Engineering Analysts, and Lab Technicians. Specific Responsibilities: • Lead the development of product requirements in collaboration with Marketing Product Managers and translate those requirements into functional specifications that define design targets. • Develop project cost estimates and partner with Marketing to present business cases. • Provide technical and design direction to CAD Design Analysts and other engineers; design assigned products to meet performance and cost objectives. • Guide lab technicians in validation testing and product evaluation. • Approve the selection of major purchased components (e.g., alternators, controllers, inverters, batteries, enclosures) and support decisions with sound engineering analysis. • Collaborate with Accounting and Procurement to track project spending and product costs, ensuring alignment with budget targets. • Validate designs through testing to meet performance, reliability, and durability goals. • Apply Design for Environment (DfE) principles to support sustainability objectives in product development. • Utilize project management skills to maintain schedules and ensure on-time delivery. • Provide clear, concise, and timely status updates on assigned projects. • Mentor junior engineers in product development processes and best practices. Requirements: • Bachelor’s degree in Mechanical Engineering from an ABET-accredited program (required). • 6+ years of experience in mechanical engineering, with a focus on new consumer product development. • Experience with Electromechanical systems a plus • Basic understanding of generators, large gaseous engines, and electrical/electronic systems, including considerations for current and future system development. • Coursework or experience related to internal combustion engines (preferred). • Power generation or generator set (genset) experience (a plus). • Demonstrated project management and leadership skills, with the ability to work effectively in a team environment. • Ability to travel domestically as required. Applicants must be authorized to work in the US without requiring sponsorship now or in the future. The Salary range for this position is $113,000.00-$143,950.00.The specific Salary rate offered to a candidate may be influenced by a variety of factors including the candidate’s experience, their education, and the work location. About Us Rehlko proudly offers a rich history steeped in creativity and commitment to our associates and communities, along with competitive benefits and compensation. Our Purpose—Creating an energy resilient world for a better future—and Values: Curiosity, Trust, Pace, and Excellence, are important cultural components that shape the way we work and relate to one another. Learn more about Rehlko at http://www.rehlko.com/who-we-are . In addition to the investment in your development, Rehlko offers a benefits package including a competitive salary, health, vision, dental, 401(k) with Rehlko matching, and more!? Rehlko is an equal opportunity employer that prohibits discrimination and will make decisions regarding employment opportunities, including, but not limited to, hiring, job assignment, compensation, promotion, benefits, training, discipline, and termination, without regard to race, creed, color, ethnicity, religion, sex, pregnancy, childbirth, or related medical conditions, genetic information, age, national origin, citizenship, ancestry, caste, mental or physical disability, marital or familial status, sexual orientation, gender identity or expression, genetic information, political belief or affiliation, union membership status, military status, veteran status, or any other characteristic protected by national, state, local, or other applicable laws. Americans with Disabilities Act (ADA) It is the policy of Rehlko to comply with all applicable provisions of the Americans with Disabilities Act (ADA) and corresponding national, state, local, or other applicable laws. Rehlko will not discriminate against any qualified associate or applicant with respect to any terms, privileges, or conditions of employment because of a person's physical or mental disability. Rehlko will provide a reasonable accommodation to associates or applicants with disabilities, in accordance with applicable laws. If you have a disability and require an accommodation in the application process or during the course of employment, please contact EnergyJobs@rehlko.com. Rehlko is an equal opportunity/affirmative action employer. Our Values Curiosity – Seek, learn, share Trust – Go farther together Pace – Focus to go faster Excellence – Find the win every day

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