Senior Manufacturing Engineer - NPI

POSITION SUMMARY

The Senior Manufacturing Engineer - NPI leads the Manufacturing Engineering delivery of new products from early design engagement through prototype, qualification, pilot build, production release and stable manufacture. The role combines senior technical manufacturing engineering with disciplined project delivery, ensuring products are manufacturable, production-ready and introduced to agreed safety, quality, delivery, cost and schedule requirements.

The post holder translates design intent into robust, repeatable and scalable manufacturing processes; coordinates cross-functional deliverables; leads build readiness, process prove-out and production trials; and retains technical ownership through ramp-up and stabilisation. This is not a stand-alone project management role. Proven hands-on NPI and industrialisation experience is essential.

CORE ACCOUNTABILITIES

• End-to-end Manufacturing Engineering ownership of assigned NPI and industrialisation programmes.
• Manufacturing readiness, process development, validation, documentation, tooling, training and production release.
• Technical ownership of assigned products through prototype, pilot build, ramp-up and stable production.
• Planning and control of engineering deliverables, milestones, risks, issues, actions and dependencies.
• Cross-functional coordination across Design, Production, Quality, Test, Supply Chain, Programme Management and suppliers.
• Delivery of capable, controlled and scalable manufacturing processes that achieve safety, quality, delivery and cost requirements.

KEY RESPONSIBILITIES

New Product Introduction and Industrialisation

• Lead Manufacturing Engineering activity across the full NPI lifecycle from concept and design reviews through prototype, qualification, pilot build, release and ramp-up.

• Create and maintain NPI manufacturing plans with clear deliverables, owners, milestones, dependencies and acceptance criteria.

• Lead Design for Manufacture and Assembly reviews and translate product requirements and design intent into practical manufacturing solutions.

• Plan and coordinate build readiness reviews, prototype and pilot builds, process prove-out, production trials and lessons learned.

• Define manufacturing process flows, routings, work content, equipment, tooling, fixtures, test interfaces, skills and training requirements.

• Ensure manufacturing readiness is evidenced before production release, including controlled documentation, capable processes, available materials, validated tooling and trained personnel.

• Lead the transfer from development into production and remain accountable for engineering support until agreed stability and performance criteria are achieved.

Manufacturing and Process Engineering

• Develop, validate and continuously improve robust, repeatable and scalable manufacturing processes.

• Lead process characterisation, verification and validation using objective data to demonstrate capability and control.

• Own and approve manufacturing documentation including SOPs, work instructions, process specifications, routings and Bills of Materials where applicable.

• Lead complex root cause investigations and implement effective corrective and preventative actions.

• Define process controls, inspection points, acceptance criteria and production KPIs.

• Drive improvements in yield, cycle time, throughput, scrap, rework, cost and delivery performance.

Engineering Project Delivery

• Lead assigned NPI, industrialisation, capacity, yield improvement, equipment and strategic Manufacturing Engineering projects from initiation through completion.
• Develop and maintain proportionate project plans, schedules, resource requirements, risks, issues, actions and dependencies.
• Define technical deliverables, milestones, success criteria and manufacturing release requirements.
• Coordinate activities across all supporting functions and challenge late or incomplete deliverables.
• Monitor progress against agreed milestones and implement recovery actions where delivery is at risk.
• Maintain clear governance through project reviews, dashboards, action logs and RAID management.
• Communicate progress, decisions, risks and support requirements clearly to stakeholders and senior leadership.

Product and Technical Ownership

• Take senior Manufacturing Engineering ownership of assigned products from NPI through ramp-up and into stable production.
• Act as the primary technical escalation point for significant manufacturing, process, material and integration issues.
• Be accountable for manufacturing performance including yield, efficiency, quality, delivery and process stability.
• Balance immediate delivery requirements with long-term process robustness, compliance, maintainability and scalability.
• Provide manufacturing input to product changes, obsolescence activity, capacity decisions and future product strategy.
• Act as technical liaison with customers, suppliers and the design authority on Manufacturing Engineering matters as required.

Technical Leadership and Team Support

• Provide technical guidance and mentorship to Manufacturing Engineers, Junior Manufacturing Engineers and Technicians.
• Set best practice for process development, documentation, structured problem solving, project control and manufacturing readiness.
• Support capability development and knowledge transfer across the Manufacturing Engineering team.
• Provide hands-on support during critical builds, trials, process prove-out and production ramp-up.
• Promote an engineering culture focused on ownership, quality, delivery and evidence-based decision-making.

Cross-Functional Collaboration and Governance

• Build effective working relationships across Design, Production, Quality, Test, Supply Chain, Programme Management and external partners.
• Facilitate technical reviews, manufacturing readiness reviews, project meetings and status reviews.
• Influence outcomes without relying on direct authority, maintaining clear ownership and constructive challenge.
• Ensure engineering deliverables comply with internal processes, quality requirements and applicable external standards.
• Maintain traceable evidence of process validation, readiness decisions, risks, actions and approvals.

PERSON SPECIFICATION

Technical and NPI Capability

• Significant manufacturing engineering experience within a production environment.
• Proven hands-on experience leading NPI and industrialisation from development or prototype builds into stable production.
• Demonstrable experience developing and validating manufacturing processes, tooling, documentation and production controls.
• Strong practical experience of build readiness, production trials, process prove-out, manufacturing release and production ramp-up.
• Ability to interpret engineering drawings, specifications, Bills of Materials and product requirements.
• Demonstrable experience leading complex problem solving, root cause analysis and corrective action.
• Project Delivery and Operational Co-ordination
• Experience planning and controlling engineering work including schedules, milestones, resources, risks, issues, actions and dependencies.
• Able to coordinate cross-functional teams and suppliers to achieve technical and delivery outcomes.
• Confident maintaining project dashboards, action logs, RAID logs and concise stakeholder reporting.
• Able to manage multiple priorities and establish practical recovery actions where delivery is at risk.

Qualifications and Technical Familiarity

• Degree, HNC/HND, apprenticeship or significant equivalent experience in Engineering, Manufacturing, Electronics, Production or a related discipline.
• Experience in hybrid microelectronics, advanced electronic assembly, semiconductor, aerospace, defence or another high-reliability environment is desirable.
• Knowledge of cleanroom operations, bonding, electronic test, high-precision assembly or special processes is desirable.
• Knowledge of ISO 9001, AS9100, ERP/MRP systems and controlled engineering documentation is desirable.
• Project Management, Lean or Six Sigma qualification is desirable.
• Leadership, Communication and Behaviour
• Technically credible, hands-on and comfortable operating at strategic and shop-floor levels.
• Structured, data-driven and disciplined in planning, prioritisation and follow-through.
• Strong communicator who can influence, challenge and align stakeholders constructively.
• Proactive, collaborative, resilient and focused on delivery without compromising safety, quality or engineering rigour.
• Able to provide technical guidance and mentorship to engineers and technicians.

Other Requirements

• Able to obtain and maintain the required Security Clearance.
• Willingness to travel occasionally where business or project needs require.
• Flexible approach to supporting critical builds, trials and production priorities.
• Commitment to continuous professional development and high engineering standards.

This job description summarises the principal responsibilities and expectations of the role. It is not exhaustive and may reasonably evolve in line with business needs and the manufacturing operating model.

Equal Opportunity Employer/Protected Veterans/Individuals with Disabilities

The contractor will not discharge or in any other manner discriminate against employees or applicants because they have inquired about, discussed, or disclosed their own pay or the pay of another employee or applicant. However, employees who have access to the compensation information of other employees or applicants as a part of their essential job functions cannot disclose the pay of other employees or applicants to individuals who do not otherwise have access to compensation information, unless the disclosure is (a) in response to a formal complaint or charge, (b) in furtherance of an investigation, proceeding, hearing, or action, including an investigation conducted by the employer, or (c) consistent with the contractor’s legal duty to furnish information. 41 CFR 60-1.35(c)
 

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