Senior Production Test Engineer

IONATE is a deep tech scale-up building the hardware and software backbone for smart grids. Our mission is to transform power systems - from grids and microgrids to renewables and data centres - unlocking the massive potential in this under-innovated sector that touches every aspect of our modern lives.

We are now looking for a Senior
Production Test Engineer to join our Operations team. You will create the production-test capability needed as the Hybrid Intelligent Transformer (HIT) moves from engineering builds into safe, repeatable manufacture at London and external manufacturing partners. You will own the production-test strategy, test methods, equipment, software, safe operating controls, test records and the test elements of manufacturing transfer, working across Engineering, Manufacturing and Quality.

This is a genuinely hands-on role. You should be happy working directly with high-power hardware, instruments, test rigs, software and technicians in the manufacturing and test area, solving problems at the equipment level. You will develop and implement production-test changes through the approved engineering change process.

• Create the production-test strategy
  . Own the production-test strategy by translating approved product requirements, design-verification evidence and known failure modes into test coverage, methods, sequences and proposed production limits, together with the records and release evidence required for each unit.
• Work directly on early units
  . Work closely with the Engineering team on production test set up and execute tests, support initial power-up and integration, capture abnormal behaviour, diagnose failures and feed practical learning back into product design, manufacturing processes and test coverage.
• Design and commission test systems
  . Specify, develop, integrate and validate test fixtures, harnesses, instrumentation, data-acquisition hardware, interlocks, software interfaces and operator controls that are safe, repeatable, maintainable and appropriate for production use.
• Engineer safe test operations
  . Define safe test methods for high-energy and high-voltage equipment, including access control, isolation, grounding, lockout and tagout, interlocks, emergency response, pre-test checks and clear operator competence requirements.
• Automate test execution and data capture
  . Develop or configure test software, scripts and interfaces that guide operators, reduce manual error, record results against the correct serialised unit and produce clear pass, fail and diagnostic evidence.
• Support fault diagnosis and corrective action
  . Use schematics, waveforms, logs, measurements and structured problem solving to isolate test failures and distinguish product defects from test-system faults. Work with Engineering, Manufacturing and Quality on containment and corrective action.
• Control test configuration and effectivity
  . Maintain approved test methods, software versions, fixtures, limits and calibration status. Implement test changes through the controlled change process and apply each change at a defined product serial number, lot, date or build stage with an auditable as-tested record.
• Optimise test performance and capacity
  . Measure test cycle time, first-pass yield, repeat tests, false failures, equipment utilisation and downtime. Improve test coverage, diagnostic value, reliability and throughput as demand grows.
• Transfer the test capability
  . Own the transfer of production-test specifications, equipment requirements, validation evidence, maintenance and calibration instructions, training and acceptance criteria to the UK contract manufacturer, with a scalable package for a future high-volume contract manufacturer.
• Contribute to PFMEA. Participate in developing and maintaining process FMEAs, ensuring that identified process risks, failure modes and required controls are translated into appropriate in-process and end-of-line production-test coverage, methods and acceptance criteria

• A genuine preference for hands-on test work
  . You enjoy working directly with products, instruments, fixtures, test software and technicians. You are comfortable setting up equipment, taking measurements, modifying test rigs and troubleshooting faults in the test area.
• Relevant production-test experience. Practical experience developing, commissioning or supporting production tests for complex electromechanical, electrical, power-electronic or similarly demanding hardware.
• Electrical fault-finding…