We are seeking an experienced Senior Manufacturing Engineer specialising in electrical and cabling systems to lead the development, industrialisation, and continuous improvement of complex electrical harness manufacturing activities from initial design release through to full-rate production.
This role will play a key part in supporting both new product introduction (NPI) programmes and the optimisation of existing manufacturing operations, ensuring products are delivered safely, efficiently, and to the highest aerospace quality standards.
The successful candidate will work closely with Design Engineering, Quality, Supply Chain, Production, and Programme teams to develop robust and scalable manufacturing solutions within a fast-paced aerospace and defence environment. The position requires a strong technical understanding of electrical harness assembly processes combined with practical experience implementing manufacturing improvements on the factory floor.
This is an excellent opportunity for a highly motivated engineer who thrives in a hands-on environment and is passionate about manufacturing excellence, process optimisation, and operational performance.
Key Responsibilities
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Lead manufacturing engineering activities for electrical harness and cabling assemblies across the full product lifecycle.
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Support New Product Introduction (NPI) activities including process development, tooling definition, work instruction creation, and production readiness reviews.
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Develop and implement efficient manufacturing processes for electrical harness assembly, including:
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Wire preparation and termination
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Crimping and soldering
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Braiding and shielding
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Potting and encapsulation
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Looming and routing
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Electrical testing and inspection
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Translate engineering designs and drawings into robust, repeatable manufacturing methods and documentation.
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Create and maintain manufacturing documentation including:
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Process specifications
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Manufacturing routings
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Standard operating procedures (SOPs)
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Work instructions
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PFMEA and control plans
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Drive continuous improvement initiatives focused on:
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Cost reduction
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Yield improvement
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Scrap and rework reduction
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Cycle time optimisation
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Right-first-time manufacturing
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Provide technical support to production teams to resolve manufacturing and quality issues in a timely manner.
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Conduct root cause investigations using structured problem-solving methodologies such as:
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8D
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RCA
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Fishbone analysis
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5 Whys
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Collaborate with Quality Engineering to ensure compliance with aerospace standards and customer requirements.
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Support design for manufacture (DFM) and design for assembly (DFA) reviews during product development stages.
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Identify and implement tooling, fixture, and process improvements to enhance manufacturing capability and repeatability.
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Participate in internal and external audits and support regulatory and customer compliance activities.
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Work closely with suppliers and subcontractors to ensure manufacturing capability and component quality requirements are achieved.
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Mentor junior engineers and production personnel on manufacturing best practices and process standards.
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Support capacity planning, line balancing, and production ramp-up activities for new and existing programmes.
