Position Summary
Magellan Aerospace has an exciting opportunity for NPI Manufacturing Engineer.
* Full time, permanent position
* 39 hours per week
* Job location: Llay, Wrexham, LL12 0PB.
* Unionised site – works in partnership with Unite the Union.
Perks And Benefits
* 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
Essential Responsibilities
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:
o Dimensional conformity
o Process capability
o 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:
o AS9100
o Airbus customer requirements
o Internal quality procedures
o Support Airbus, internal, and regulatory audits related to NPI and work transfer
o 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
Position Requirements
Academic:
* Bachelor's degree in Mechanical, Manufacturing, or Aerospace Engineering
Experience:
* 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)
Key Competencies:
* 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 mindset
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