We have an exciting opportunity for an experienced Design and Production Engineer to join our team based in Daventry, Northamptonshire.
RA delivers a wide range of services and innovative products, designed to exceed the exacting specifications and quality requirements of its customers.
Role Purpose:
As a Design and Production Engineer at Red Arch, you’ll turn ideas into precision-engineered reality — developing innovative exhaust and powertrain systems for world-class automotive brands and leading their journey from prototype to production, transforming into efficient, high-quality manufacturing processes that meet demanding quality, cost, and delivery targets.
Working closely with serial production, quality, and suppliers, you’ll ensure every design not only looks exceptional but is built efficiently and repeatably. The role demands creativity, technical rigour, and a passion for engineering. You will support and contribute to internal and customer meetings. Your work will define the precision, performance, and craftsmanship that set every Red Arch product apart.
Key Responsibilities
1) Concept & Feasibility
- Generate and develop CAD concepts using CATIA V5 (surface, solid, and 2D) based on customer data and packaging constraints.
- Provide early design and manufacturing input to assess feasibility, cost, and capability, coordinating with internal teams and suppliers.
- Prepare and maintain the Manufacturing Feasibility Report (MFR) throughout all project phases.
- Lead and Support Design FMEA and Manufacturing Feasibility Reviews to identify and mitigate potential risks early.
- Define datum structures, interfaces, layouts, and special characteristics in line with customer, internal, and APQP standards.
- Present design proposals and technical solutions at internal gateway and design review meetings.
2) Prototype Development & Validation
- Create detailed CAD models and drawings for prototype manufacture and customer approval.
- Design and commission tools, jigs, and fixtures for prototype and production use.
- Plan and manage prototype builds, coordinating internal teams, suppliers, tooling, and manufacturing activities.
- Review first-off parts with the Quality Team, analyse measurement data, and implement design or process adjustments as required.
- Lead and Support DFMEA and PFMEA development to identify and control product and process risks.
- Capture and document lessons learned from prototype builds to support design freeze and production readiness.
3) Pre-Production & Industrialisation
- Finalise designs for production release, ensuring correct application of GD&T, robust datum structures, and tolerance stack-ups.
- Develop and validate process flows, PFMEA, Control Plans, and Standard Operating Procedures for pre-production builds, ensuring all SC/CC characteristics are included.
- Conduct capacity studies, layout reviews, and Run-at-Rate trials to confirm process stability and cycle-time targets.
- Oversee tooling readiness and sign-off, working with both in-house and external suppliers.
- Maintain CAD data accuracy and configuration control throughout development.
- Review process and measurement feedback from pilot builds to refine product and tooling design.
- Ensure routings, and process changes are correctly defined in Factory Master or ERP systems.
4) Production Launch & Continuous Improvement
- Support production ramp-up by resolving design or process issues promptly and effectively.
- Lead process capability (under guidance) and efficiency improvements to achieve cost, quality, and delivery targets.
- Lead and Participate in Run-at-Rate reviews, lessons-learned sessions, and cross-functional improvement workshops.
- Contribute to the continuous improvement of design standards, CAD practices, and manufacturing methods.
- Document and share lessons learned for future New Product Introduction (NPI) projects.
Qualifications & Experience
· Degree or HND in Mechanical, Manufacturing, or Production Engineering (or equivalent technical experience). Preferred.
· Skilled in CATIA V5 for 3D modelling and 2D engineering drawings. Required.
· Proficient in Datum Structures and GD&T to BS8888 / ASME Y14.x standards.
· Strong understanding of production processes, tooling design, and design-for-manufacture (DFM) principles.
· Familiarity with APQP, PFMEA, Control Plans, and Lean manufacturing methods.
· Familiarity with IATF 16949 and related quality management systems.
· Proficient in Microsoft Office (Word, Excel, PowerPoint); experience with ERP or Factory Master is an advantage.
Skills & Attributes
· Practical, proactive, and detail-driven with a hands-on approach to engineering.
· Self-motivated, organised, and able to work independently or collaboratively within cross-functional teams.
· Strong communication and interpersonal skills, both written and verbal.
· Analytical and structured problem-solver, familiar with Six Sigma, 8D, Ishikawa, and Poka-Yoke tools.
· Capable of managing multiple projects, prioritising effectively, and adapting to fast-changing demands.
· Flexible, resourceful, and solution-focused, with a mindset of continuous improvement.
· Committed to maintaining the highest standards of safety, quality, and operational excellence.
Relevant Experience
· Experience of working within an engineering design and manufacturing environment – background in new product introduction (NPI) and process development.
· Experience of the automotive industry, although a military vehicle background would be considered similar.
· Automotive Tier 1 or OEM experienced.
· Other sectors such as Chemical Process, Mining, Rail, Aerospace, Marine, etc will be considered.
If you are interested in this role, please submit a CV.
Salary - up to £35,000 per annum (negotiable dependent on experience)
Benefits include; Pension Scheme, Death in Service, EAP, 25 days annual leave plus bank holidays. 37.5 hour working week (8am -4pm, Monday - Friday), Free onsite parking and annual pay reviews.
Job Types: Full-time, Permanent
Pay: Up to £38,000.00 per year
Benefits:
- Health & wellbeing programme
- Life insurance
- On-site parking
Work authorisation:
- United Kingdom (required)
Work Location: In person
