Staff Mechanical Engineer, VE

We are Generac, a leading energy technology company committed to powering a smarter world.

Over the 60 plus years of Generac’s history, we’ve been dedicated to energy innovation. From creating the home standby generator market category, to our current evolution into an energy technology solutions company, we continue to push new boundaries.

Generac is a leading technology company dedicated to designing and manufacturing cutting-edge power systems and solutions. Our innovative products cater to various industries, including renewable energy and grid-tied systems.

We're seeking a Staff Mechanical Value Engineer with a unique blend of industrial engineering expertise and mechanical product knowledge to drive cost optimization and Value Analysis (VA) across our clean energy product portfolio. In this strategic role, you'll not only own the Mechanical Costed Bill of Materials (MCBOM) and develop dynamic cost models, but you'll also serve as a cost optimization advisor to our mechanical engineering team—guiding engineers on cost-effective design decisions and leading cross-functional projects that deliver measurable savings.

This is a high-impact individual contributor role where you'll combine analytical rigor with manufacturing expertise to identify opportunities, influence design decisions, and drive projects to completion autonomously. Your work will directly shape the cost competitiveness of Generac's solar inverters, battery storage systems, and related clean energy products.

Roles and Responsibilities:

• Serve as the cost optimization expert for the mechanical engineering team—providing guidance, methodologies, and best practices for cost-effective design

• Coach and mentor mechanical engineers on Design for Manufacturability (DFM), Design for Assembly (DFA), and cost-driven design principles

• Lead technical design reviews with a cost optimization lens, challenging assumptions and identifying opportunities early

• Develop and disseminate cost optimization frameworks and tools that the engineering team can leverage independently

• Create design guidelines that embed cost consciousness into the engineering workflow

• Develop, maintain, and continuously improve dynamic cost models for mechanical components and assemblies across both new product development (NPI) and sustaining engineering programs

• Own the Mechanical Costed Bill of Materials (MCBOM) and ensure accuracy at all stages of product development—from concept through production

• Conduct should-cost analysis using industrial engineering principles: time studies, work content analysis, process capability assessment

• Build parametric cost models that engineers can use to evaluate design trade-offs in real-time

• Identify cost drivers and quantify the financial impact of design decisions with data-driven analysis

• Proactively identify and prioritize opportunities for cost reduction and cost avoidance across the mechanical product portfolio

• Plan, lead, and execute major value engineering projects from concept to realized savings

• Drive systematic cost optimization initiatives using industrial engineering methodologies (process mapping, waste elimination, standardization)

• Develop business cases and ROI analyses for proposed design and process changes

• Track and report project progress, savings realized, and cost avoidance metrics

• Partner with mechanical design engineers to influence cost-effective design decisions throughout the development cycle

• Collaborate with manufacturing engineering to optimize production processes and reduce labor content

• Work with quality and test teams to ensure cost optimizations don't compromise product performance or reliability

• Support sourcing team during RFQ processes with detailed should-cost models and technical cost assessments

• Facilitate communication between engineering, operations, and commercial teams to align on cost targets and trade-offs

Supplier & Manufacturing Process Expertise:

• Conduct periodic supplier visits (up to 30% travel) to understand manufacturing processes, capabilities, and cost structures

• Apply industrial engineering principles to analyze supplier operations and identify improvement opportunities

• Challenge supplier quotes with detailed should-cost analysis based on process understanding

• Collaborate with suppliers on value engineering proposals and design optimization opportunities

• Assess manufacturing feasibility and cost implications of design alternatives

Minimum Job Requirements:

• Bachelor’s degree in industrial engineering, Manufacturing Engineering, or Mechanical Engineering (Industrial Engineering strongly preferred)

• 10+ years of experience combining:

• Industrial engineering (cost analysis, process optimization, time studies, work measurement)

• Mechanical product design and development

• High-volume manufacturing environment experience

• Cost modeling, should-cost analysis, and MCBOM management

• Industrial engineering methodologies (Lean, process mapping, time studies, capacity analysis)

• Coaching and influencing engineering teams on cost optimization

• Proven track record of leading value engineering projects with measurable cost savings and team impact

• Experience working with suppliers on cost negotiations, process improvements, and technical discussions

• Proficiency with CAD software (SolidWorks, CREO, or similar) to evaluate designs and identify optimization opportunities

• Advanced analytical skills with Excel and cost modeling tools

• Excellent communication and coaching skills to guide engineers, influence decisions, and translate technical concepts into financial impact

• Strong cross-functional collaboration skills with ability to influence without direct authority

• Ability to travel up to 30% including occasional international travel

Preferred Qualifications:

• Master’s degree in industrial engineering or related field

• Lean Six Sigma certification (Green Belt or Black Belt)

• Certified Value Specialist (CVS) or formal Value Engineering training

• Experience in solar, renewable energy, power electronics, or outdoor electrical equipment industries and related tax credits

• Knowledge of environmental requirements for outdoor-rated products (IP ratings, NEMA enclosures, UL standards)

• Familiarity with UL/safety certification processes and their cost implications

• Experience with cost modeling software (aPriori, Siemens Teamcenter, or similar platforms)

• Understanding of supply chain dynamics including Asian sourcing strategies, tariffs, and commodity markets

• Background with ERP/PLM systems (SAP, Oracle, Windchill, etc.)

• Experience with thermal management design for power electronics

• Track record of building cost optimization capabilities within engineering organizations

• Experience working with both NPI and sustaining engineering cost optimization

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. Occasional travel.

“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.”