Kingsway Group is a world-leading designer and manufacturer of doorsets and accessories for mental-health and secure-care environments. Continued growth has created a new opportunity for an EPD Engineer to join our Product team and drive quality, cost and delivery improvements across our in-market portfolio.
This hands-on role sits between Design, Production, Quality, Supply and Installation Engineering. You'll stabilise and evolve current products, resolve field issues, value-engineer components, and ensure we can build right-first-time at scale.
Role Overview
* Own sustaining engineering for assigned products (doorsets, vision panels, hardware, washroom items).
* Triage, root-cause and permanently fix product and manufacturing issues (8D, 5-Whys, fishbone).
* Lead ECR/ECN change control, updating drawings, specs, BOMs, routings and work instructions.
* Deliver value engineering and standardisation (cost-down, de-risk, supply continuity, obsolescence).
* Partner with Production on DFM/DFA, jigs/fixtures.
* Build and test quick prototypes; run verification on updates before release.
* Keep product data clean and current in PDM/ERP; maintain golden thread of revisions.
* Support global sites (UK/US/AUS) with build issues, supplier queries and installer feedback.
* Collaborate with Quality to close NCRs/CAPAs and prevent recurrence.
* Prepare crisp technical packs: updated drawings, labels, assembly guides and install/O&M content.
What You'll Do Day-to-Day
* Investigate factory/field problems, define CTQs, implement and validate fixes.
* Create/modify 3D CAD and BS 8888-compliant 2D drawings; run tolerance stacks.
* Run pilot builds; prove process capability with Production; hand over robustly.
* Work with Supply Chain on alternate parts, cost savings and risk mitigation.
* Track actions and outcomes against clear KPIs (FPY, scrap, warranty, unit cost, OTIF).
Requirements
* SolidWorks proficiency and strong 2D drawing discipline (BS 8888).
* Proven EPD/sustaining engineering experience in electromechanical or building-product assemblies.
* Strong grasp of materials and processes (sheet metal, machining, coatings, joinery, glazing, assembly).
* Comfortable with hands-on bench work, fixtures and prototype builds.
* PDM experience preferred; working knowledge of ERP BOM/routing control.
* Competent in DFM/DFA, tolerance analysis and basic statistical validation.
* Clear communicator who thrives cross-functionally and under time pressure.
* Relevant qualification (BEng/BSc or equivalent).
Nice to have: exposure to doors/hardware; familiarity with fire/smoke testing workflows; experience supporting multi-site manufacturing.
Terms
* Hours: 8:00–17:00, Mon–Fri.
* Location: Kingsway offices (DA14 5BN).
* Hybrid: up to 2 days/week remote at line manager's discretion.
* Equipment: Laptop provided.
* Benefits: 25 days holiday (plus Bank Holidays), pension scheme, on-site parking and food.