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
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
* Perkbox – includes monthly treats and discounts from selected restaurants, cinemas, shops etc.
* 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
* 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.
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
About Us
Magellan Aerospace is a global, integrated aerospace company that provides complex assemblies and systems solutions to aircraft and engine manufacturers, defence and space agencies worldwide. The organization officially adopted the name Magellan Aerospace Corporation in 1996; deriving it from the intrepid explorer Ferdinand Magellan. His global exploits at the turn of the 15th century established a number of firsts, so the company’s vision has been to carry this same legacy into the future of the aerospace industry.
At Magellan, we have over 80 years of collective knowledge and experience in the aerospace industry, and believe one truth: People create value. Employees are our greatest resource in working towards a successful future, and together we build professional relationships that thrive. We know that personal development is fundamental to the success of every individual, and every individual is fundamental to the success of our business, so we invest in our employees and provide excellent career progression opportunities. When you are part of Magellan, you are part of the team!
Confidentiality
Magellan Aerospace respects the privacy and confidentiality of personal information provided by candidates and shall not disclose to any external parties unless legislated.
Thank you for considering this exciting opportunity. This document is intended to provide the reader with information and is not a contractual document. Some of the material therefore may be subject to change.
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