Manufacturing / Production Engineer – Underwater Systems and Sonar Contract / Consultant
Clearance Required: Must have or be eligible for SC / DV clearance
Role Overview:
We are seeking a highly capable Manufacturing / Production Engineer to support the establishment of a new production line at a key supplier. This role is critical in ensuring that manufacturing capability for underwater systems — including transducers and sonar equipment — is successfully transferred, commissioned, and quality assured.
The successful candidate will bring hands-on experience of setting up manufacturing operations, ideally within the underwater systems, transducers, or sonar technology domains, and will act as a bridge between engineering, quality assurance, and supplier operations teams.
Key Responsibilities:
Support the setup and qualification of a new manufacturing line at an external supplier site.
Define and optimise production processes for underwater acoustic products (transducers, sonar arrays, related subsystems).
Collaborate with design engineering teams to ensure manufacturability (DfM) and adherence to quality standards.
Develop and approve production documentation, including build instructions, test procedures, tooling specifications, and quality plans.
Oversee production trials and first article inspections (FAI) to validate process capability and product conformity.
Drive process improvements and corrective actions where required to meet quality, cost, and schedule goals.
Interface directly with suppliers, providing technical support and operational guidance.
Implement production control and reporting systems (e.g., KPIs, yield, defect tracking) as required.
Ensure compliance with applicable standards (e.g., ISO 9001, AS9100, defence/marine quality standards).
Support risk identification and mitigation activities during production transfer and ramp-up phases.
Essential Skills and Experience:
Strong background in manufacturing engineering, production engineering, or industrialisation.
Experience setting up or transferring manufacturing lines, ideally within a regulated or defence environment.
Familiarity with underwater systems manufacturing — such as transducers, sonar arrays, pressure vessels, composite structures, or sealed electronics.
Working knowledge of acoustic transducer fabrication methods (e.g., piezoelectric element bonding, potting, assembly techniques).
Proven ability to liaise between engineering teams, suppliers, and internal operations.
Hands-on experience with quality tools such as FMEA, PPAP, Control Plans, and Root Cause Analysis (e.g., 8D).
Excellent written and verbal communication skills for reporting and documentation.
Able to travel to supplier locations as needed during project phases.
Desirable Experience:
Experience with defence sector sonar and underwater acoustic systems.
Knowledge of special manufacturing requirements for marine environments (e.g., watertight seals, pressure testing, corrosion protection).
Experience working with low-volume, high-complexity, high-reliability production.
Familiarity with Lean Manufacturing and Six Sigma methodologies.
Qualifications:
Degree, HND, or equivalent experience in Mechanical, Manufacturing, or Production Engineering (or a related field).
Additional qualifications in Quality Management or Industrial Engineering are advantageous.
Green Belt or higher Six Sigma certification (desirable but not essential).