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).