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Sussex, Wisconsin, United States
Onsite
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The Senior Generator Tester is expected to perform system tests, conform to production and quality standards, analyze failure modes, and perform minor repairs in workstation. The tester ensures all records are kept and confers with appropriate resources when issues arise.
Senior Generator Tester
Primary Purpose
The Senior Generator Tester is a highly skilled technical resource responsible for performing advanced system testing, troubleshooting complex product issues, supporting new product introductions, and ensuring efficient product flow through the Test area. This role serves as a subject matter expert for testing processes, quality standards, and product functionality while partnering closely with Engineering, Quality, Maintenance, and Production teams. The Senior Generator Tester is expected to train and mentor other testers, support continuous improvement initiatives, and drive testing excellence across all product lines.
Major Responsibilities
Safety & Quality
Comply with all company and site safety, quality, and environmental policies, procedures, and standards. Maintain a clean and organized work area in accordance with 5S principles. Ensure all testing activities meet established quality requirements and production standards. Obtain and maintain certifications required to safely move and test products.
Testing & Troubleshooting
Perform testing on all products, models, and subassemblies using established work instructions, programs, and standard work. Interpret schematics, wiring diagrams, specifications, and technical documentation to properly test products.
Troubleshoot complex product, process, and equipment issues utilizing advanced diagnostic techniques.
Analyze failure modes and determine root causes using structured problem-solving methodologies such as 5 Why, PDCA, and 8D. Perform repairs and corrective actions within established standards and escalate issues when necessary.
Program systems and controls as required to support product testing.
Technical Leadership
Serve as a technical expert on testing processes, product functionality, quality concerns, and troubleshooting activities.
Partner closely with Engineering to develop, validate, and improve testing procedures.
Support new product introductions by assisting with test setup, validation, troubleshooting, and process development.
Lead technical investigations and recommend corrective actions to improve product quality and reliability.
Identify opportunities to improve test methods, equipment utilization, throughput, and efficiency.
Training & Mentorship
Train and mentor Tester I, II, and III employees on testing processes, troubleshooting techniques, and standard work.
Support skill development and progression of team members through hands-on coaching and knowledge sharing.
Assist in developing and maintaining training materials, work instructions, and testing documentation.
Continuous Improvement
Participate in Continuous Improvement (CI), Design-to-Zero (DTZ), and New Product Introduction (NPI) initiatives. Collaborate with cross-functional teams to improve safety, quality, productivity, lead times, and cost.
Identify preventative maintenance opportunities and communicate recommendations to the Maintenance team.
Operational Support
Monitor testing cycle times and product flow to ensure production schedules are met.
Assist leadership in prioritizing workloads and resolving bottlenecks within the Test area.
Provide technical support to production, quality, maintenance, and engineering teams as needed.
Perform additional duties and support other departments as assigned.
Minimum Job Requirements
Education
High School Diploma or equivalent required.
Preferred Education
Associate Degree in Automated Technology, Electro-Mechanical Technology, Electrical Technology, or a related technical field preferred.
Work Experience
Four or more years of product testing, troubleshooting, electrical diagnostics, or related manufacturing experience required.
Demonstrated experience performing advanced troubleshooting on electrical, mechanical, and control systems required. Previous experience training and mentoring employees in a manufacturing environment required.
Experience supporting new product introductions, process improvements, or engineering initiatives preferred.
Knowledge, Skills & Abilities
Advanced knowledge of manufacturing testing processes and equipment.
Strong electrical and mechanical troubleshooting skills. Ability to read and interpret electrical schematics, wiring diagrams, and technical drawings.
Advanced root cause analysis and problem-solving capabilities.
Strong understanding of quality systems and manufacturing processes.
Experience using SAP or equivalent ERP systems. Intermediate to advanced computer skills.
Effective written and verbal communication skills.
Ability to work independently with minimal supervision.
Ability to prioritize multiple tasks and adapt to changing production demands.
Proven ability to train, mentor, and develop employees. Demonstrated leadership and teamwork skills.
Level of Independence
Works independently under minimal supervision.
Provides technical guidance and direction to other Test personnel and serves as a resource for cross-functional teams.
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.
“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.”