Senior Manufacturing Engineer - Electronics

Senior Manufacturing Engineer - Electronics Assembly Specialist

Location: Wiltshire, UK

Security Clearance: Eligible for UK SC Clearance & BPSS

The Opportunity

We are expanding our UK manufacturing operations to support the production of advanced Unmanned Aerial Systems (UAS) and are looking for a Senior Manufacturing Engineer with specialist expertise in electronics assembly manufacturing.

This role will take ownership of the processes, standards, and manufacturing methods that support the build of high-reliability electronic assemblies, including SMT, through-hole, PCB, and harness assemblies. Working within a regulated aerospace manufacturing environment, you will be responsible for developing robust and repeatable production processes that enable quality, efficiency, and scalability as manufacturing operations continue to grow.

As a key member of the Manufacturing Engineering team, you will work closely with Product Engineering, Production, Quality, and Supply Chain functions to introduce new products, optimise existing processes, and ensure compliance with IPC workmanship standards and aerospace quality requirements. The role offers the opportunity to make a significant impact on manufacturing performance and help establish best-in-class electronics assembly capabilities within a rapidly developing production environment.

Key Responsibilities

Process Development & Industrialisation

• Develop, implement, validate, and continuously improve manufacturing processes for electronic assemblies, including:
  • Surface Mount Technology (SMT)
  • Through-hole assembly
  • PCB assembly and integration
  • Harness and cable assembly
• Support the transfer and implementation of manufacturing processes into UK production operations.
• Create and maintain manufacturing documentation, including work instructions, routings, process flows, standard operating procedures, and build documentation.
• Support New Product Introduction (NPI) activities, ensuring products are successfully transitioned from development and prototype build stages into repeatable production.
• Lead process validation, production readiness reviews, and industrialisation activities to support manufacturing growth.

Quality & Manufacturing Control

• Ensure manufacturing processes operate in accordance with IPC-A-610, IPC/WHMA-A-620, AS9100, and other applicable quality standards.
• Develop and maintain PFMEAs, Control Plans, process control documentation, and validation records.
• Lead root cause investigations and corrective action activities relating to:
  • Soldering and workmanship defects
  • PCB assembly issues
  • Component placement concerns
  • Harness and cable assembly non-conformances
  • Recurring production defects and escapes
• Drive measurable improvements in First Pass Yield, production stability, defect reduction, and rework performance.
• Work closely with Quality teams to ensure robust process control and compliance across manufacturing operations.

Tooling, Fixtures & Equipment

• Specify, develop, and implement manufacturing tooling, jigs, fixtures, and assembly aids to improve quality, efficiency, and repeatability.
• Support inspection technologies, automated optical inspection (AOI), and test equipment optimisation.
• Ensure production equipment remains appropriately qualified, calibrated, and fit for purpose.
• Identify opportunities for automation and process enhancement where appropriate.

Continuous Improvement

• Lead Lean Manufacturing and Continuous Improvement initiatives across electronics manufacturing processes.
• Analyse production performance data to identify opportunities for quality, throughput, and efficiency improvements.
• Reduce manufacturing cycle times, bottlenecks, waste, and non-value-added activities.
• Standardise best practices and manufacturing methods across existing and future product lines.

Cross-Functional Collaboration

• Collaborate with Product Engineering, Production, Supply Chain, and Quality teams throughout the product lifecycle.
• Support engineering change implementation and ensure changes are effectively introduced into manufacturing operations.
• Provide technical guidance and support to operators, technicians, and production teams.
• Act as the subject matter expert for electronics assembly processes, workmanship standards, and manufacturing best practice.

Essential Skills & Experience

Electronics Manufacturing

• Proven hands-on experience within electronics manufacturing engineering environments.
• Strong background in SMT assembly process development and optimisation.
• Experience supporting through-hole assembly manufacturing processes.
• Experience with harness and cable assembly production methods.
• PCB assembly industrialisation and manufacturing process development experience.
• Experience implementing and validating manufacturing processes in production environments.
• Demonstrable involvement in NPI, product industrialisation, and production scale-up activities.

Quality & Compliance

• Practical application of IPC-A-610 within a manufacturing environment.
• Practical application of IPC/WHMA-A-620 within a manufacturing environment.
• Experience working within AS9100, ISO 9001, or similarly regulated quality management systems.
• Experience developing PFMEAs, Control Plans, and process validation documentation.

Manufacturing Engineering

• Strong shop-floor manufacturing process ownership and problem-solving capability.
• Experience conducting Root Cause Analysis and implementing effective corrective actions.
• Knowledge of Lean Manufacturing and Continuous Improvement methodologies.
• Ability to develop, document, and standardise manufacturing processes and work instructions.

Desirable Experience

• Defence electronics manufacturing
• Aerospace electronics production
• Avionics manufacturing
• Unmanned Aerial Systems (UAS/UAV) integration
• Automated Optical Inspection (AOI)
• Conformal coating processes
• ESD control and management programmes
• Supplier industrialisation and development
• Environmental and vibration qualification support
• Low-volume, high-complexity manufacturing environments
• Rapid product introduction and scaling programmes
• Six Sigma or equivalent process improvement methodologies

Candidates without direct electronics assembly manufacturing experience, IPC standards application, or experience within a regulated production environment are unlikely to be suitable for this position.