Manufacturing Engineer - NPI

Morson are recruiting for a Manufacturing Engineer – NPI & Industrialisation to join a leading aerospace manufacturing organisation based in Wolverhampton , supporting the development and manufacture of advanced Flight Control Actuation Systems within the Civil Value Stream. This is a technically focused and delivery-driven role where you will play a key part in the industrialisation of next-generation aerospace products, ensuring manufacturing readiness from early design phases through to production launch.

Working at the forefront of New Product Introduction (NPI), you will lead the development, validation and optimisation of manufacturing processes, ensuring products are designed for manufacture, assembly and automation. You will collaborate closely with Design Engineering, Quality, Supply Chain, Operations, Programmes and external suppliers to deliver robust, lean and capable manufacturing solutions. This is an excellent opportunity to work within a Tier 1 aerospace environment supporting complex electromechanical systems, advanced manufacturing technologies and future aircraft programmes.

Key Responsibilities Lead New Product Introduction (NPI) and industrialisation activities, ensuring manufacturing readiness is achieved to programme milestones Develop, implement and optimise manufacturing processes that deliver safety, quality, cost and delivery objectives Lead APQP activities including:
Process Flow Diagrams PFMEA Control Plans Process Validation Production Readiness Reviews Establish and manage Manufacturing Readiness Levels (MRLs) and drive mitigation plans for manufacturing risks Use SPC, capability analysis and structured problem-solving techniques to improve process capability and manufacturing performance Define manufacturing methods, routings, Bills of Materials (BOMs), standard work and process documentation Work closely with Design Engineering teams to ensure Design for Manufacture (DFM), Design for Assembly (DFA) and Design for Automation principles are incorporated within product designs Evaluate and implement manufacturing technologies, automation solutions and machine vision systems Lead manufacturing trials, process qualification and validation activities including first article support and capability studies Support supplier industrialisation activities, capability assessments and Make vs Buy evaluations Act as a technical interface between customers, suppliers and internal stakeholders Support continuous improvement initiatives and manufacturing technology roadmaps Apply process risk reduction methodologies including PFMEA and other recognised risk management tools Support the development of manufacturing standards, specifications and engineering procedures Requirements

Experience with in aerospace, defence or other highly regulated manufacturing environments Proven experience delivering New Product Introduction (NPI), industrialisation or manufacturing transfer programmes Strong understanding of APQP methodologies including PFMEA, Control Plans and process validation Experience developing and implementing manufacturing processes and production systems Strong understanding of engineering drawings, technical specifications and manufacturing requirements Experience working with cross-functional teams, suppliers and equipment providers Knowledge of Design for Manufacture (DFM), Design for Assembly (DFA) and Design for Automation principles Understanding of Lean Manufacturing and continuous improvement methodologies HNC/HND, Degree or equivalent experience in Manufacturing, Mechanical, Production or Aerospace Engineering Strong stakeholder management and problem-solving capabilities Desirable Aerospace assembly and test experience, ideally supporting flight control, actuation or electromechanical systems Experience developing or industrialising welding and joining processes Knowledge of Manufacturing Readiness Levels (MRLs)

Experience with SPC, process capability studies and variation reduction techniques Machine vision systems, automated inspection or advanced manufacturing technologies experience Knowledge of special process qualification and control requirements Lean Six Sigma qualification or equivalent practical experience Project management training or qualifications (PRINCE2, APMP or equivalent) Degree in Aerospace, Mechanical or Manufacturing Engineering About the Role This position sits within a major aerospace programme focused on the industrialisation and manufacture of advanced Flight Control Actuation Systems for future aircraft applications.

The role is heavily focused on NPI, manufacturing readiness and industrialisation, requiring a hands-on engineer capable of influencing design, developing manufacturing processes and driving production capability improvements. Working closely with internal engineering teams, operations, suppliers and customers, you will help bridge the gap between product design and successful production delivery, ensuring robust and scalable…