NPI Manufacturing Engineer

Position Summary

Magellan Aerospace has an exciting opportunity for NPI Manufacturing Engineer.

• Full time, permanent position
• 39 hours per week
• Unionised site – works in partnership with Unite the Union.
• Job location:
  
  Llay, Wrexham, LL12 0PB
  .

• A company culture that promotes work life balance
• Access to mental health support
• Business performance related bonus
• Career development opportunities
• Commitment to continued learning and development
• Long Service Awards
• Enhanced Holiday Entitlement based on length of service
• Free parking
• 25% off local gym membership

Manufacturing Planning & Industrialisation

• Lead manufacturing process definition and industrialisation activities aligned to Airbus WT milestones
• Develop and maintain manufacturing routings, process flows, and work instructions
• Support industrial maturity and Manufacturing Readiness Level (MRL) assessments for machining processes
• Ensure processes are production-ready prior to gate progression and serial release

Machining Engineering – Aluminium Structural Parts

• Develop and validate CNC machining processes for aluminium wing structural components
• Define machining strategies, tooling concepts, fixtures, and cutting parameters
• Collaborate with CAM programming teams to optimise toolpaths, cycle time, and machining stability
• Ensure machining processes meet Airbus technical, dimensional, and capability requirements

First‑Off & Process Validation

• Support first‑off manufacturing builds and process prove‑out activities
• Support First Article Inspection (FAI) activities in accordance with EN/AS9102 and Airbus requirements
• Ensure gate‑required validation activities are completed, including:
• Dimensional conformity
• Process capability
• Tooling and fixture validation
• Support closure of manufacturing‑related open points prior to gate approval

Production Ramp‑Up & Industrial Support

• Provide hands‑on manufacturing engineering support during LRIP and rate ramp‑up
• Troubleshoot machining, tooling, and process issues on the shop floor
• Support transition from NPI to stable serial production

Risk Management & Issue Resolution

• Identify and manage manufacturing risks affecting gate progression (capacity, process stability, tooling readiness)
• Lead or support root cause analysis and corrective actions for NPI and work transfer issues
• Ensure robust containment and corrective actions are implemented prior to serial release

Compliance & Audit Support

• Ensure compliance with AS9100, Airbus customer requirements, and internal quality procedures
• Support Airbus, internal, and regulatory audits related to NPI and work transfer
• Maintain accurate and auditable manufacturing documentation supporting gate decisions

Continuous Improvement & Lessons Learned

• Capture lessons learned during NPI and work transfer activities
• Feed lessons learned back into standard machining and industrialisation processes
• Support continuous improvement initiatives focused on cycle time reduction, yield improvement, and industrial risk reduction

Attend daily/weekly sessions to update on progress

Support the NPI process as and when required

• Bachelor's degree in Mechanical, Manufacturing, or Aerospace Engineering

• 3-7 years of manufacturing engineering experience in aerospace machining
• Experience supporting NPI, industrialisation, or work transfer activities
• Strong understanding of CNC machining for aluminium structural aerospace components
• Direct experience working with Airbus programs or within the Airbus supply chain
• Familiarity with Airbus Gated Work Transfer, Manufacturing Gates, or MFT/IPT environments
• Experience with machining of aluminium alloys (e.g., 2024, 7050, 7075)
• Knowledge of industrial maturity, MRL, and process capability concepts
• Lean Manufacturing or Six Sigma Green Belt (preferred)

• Strong stakeholder management in a gated, milestone‑driven environment
• Ability to assess manufacturing readiness using objective evidence and data
• Structured, risk‑based problem‑solving approach
• Strong communication across manufacturing, quality, and supply chain teams
• High attention to detail and documentation discipline
• Hands‑on, shop‑floor‑focused mind set