Senior Project and Design Engineer

Job Title: Senior Project and Design Engineer

Requisition ID: 10458

Location: Newport, Wales, GB, NP19 4XJ

Home-based Position: No

Regular/Temporary: Regular

Job Type: Full-Time

Job Purpose

Reporting directly to the Site Engineering Manager, the Senior Project and Design Engineer will work closely with Process Engineering, Technical, Production, Product Design, and Quality teams to ensure all CapEx projects and new products or existing products transition from Design or other sister plants to Production seamlessly by executing projects in new tooling, and assembly process design and commissioning in readiness for SOP.

Essential Duties and Responsibilities

• Lead the development of new processes, from early-stage product concepts to building product samples in line with New Product Introduction (NPI) procedure, Quality system, and Development Process.
• Work with Engineering Design and Senior Manufacturing Engineering teams to ensure optimum product and process design for manufacturability for New Product Introduction.
• Responsible for tooling design and maintenance of tooling drawings database.
• Help with the design of small assemblies or subassemblies for existing machines.
• Carry out engineering and design analysis using ANSYS and other FEA tools.
• Lead the development and design of manufacturing systems and validate design.
• Support development of associated documentation and estimates of manufacturing cost.
• Contribute as a key member of strategic allocated work-streams within technical projects to meet project targets and ensure product exceeds customer expectations and operational needs.
• As a key member of the engineering team, investigate all manufacturing solutions and liaise with Process Engineering Technical, Production, and Quality to ensure agreed production systems are in place.

Key Responsibilities

• Develop technical specifications for new manufacturing systems and machinery and write invitation to tender documents.
• Compile detailed cost estimates and agree budgets with the engineering manager for capital requests.
• Advise and coordinate with the technical and process engineering team on any new equipment, tooling, process design, process changes/modifications required for new products or process improvements, ensuring the lead times are considered against project plans for product launches.
• Review existing manufacturing systems and select appropriate modern manufacturing techniques and implement to drive efficiency, cost, and quality improvement.
• Make decisions within remit and escalate issues with significant risk/implication to the Engineering Manager.
• Lead and take ownership of all site projects from specification development, concept design, detailed design, cost estimates, tender, sign off drawings, FAT, SAT, commissioning, validation, training, SOPs, and beneficial operation handover.
• Train and mentor junior engineers and apprentices.
• Task manage other engineers and technicians and review the technical aspect of assigned projects to ensure project objectives are met.

Skills and Competencies

• Experienced in concept design of automated lean assembly manufacturing lines.
• Ability to lead on allocated projects with a budget up to £1 million.
• Expert knowledge in continuous improvement methods to improve overall equipment effectiveness (OEE), quality, reduce cost, inefficiencies, and waste.
• Skilled in methods engineering, time and motion study, and assembly line balancing.
• Skilled in PFMEA, SPC, MSA, PPAP, and VDA 6.3 tools.
• Skilled in Microsoft Project for planning and resource loading.
• Skilled in the use of 2D and 3D CAD systems and manufacturing simulation and modeling packages e.g., AutoCAD, Creo, SolidWorks, DFMEA, visual components, etc.
• Ability to work in a multi-functional team and to build relationships with peers and effectively communicate complex technical concepts to different audiences and senior stakeholders in simplistic terms.
• Team leadership experience in a high-paced manufacturing environment.

Qualifications

• A BSc/BEng/MEng degree or HND in Manufacturing Systems, Industrial or Mechanical Engineering with over 5 years’ experience in a similar role.
• Lean Six Sigma Blackbelt or Green Belt qualified.

EnerSys provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws. EEO/Minority/Female/Vets/Disabled.