Senior Production Engineer in Horsham

RolePurpose:

The Senior Production Engineer is a technical leader responsible for defining, developing, and optimising the end-to-end production capability for defence-grade hardware systems. This role provides strategic influence across design, industrialisation, and full-rate manufacturing,ensuringproductsareengineeredforreliability,regulatorycompliance,and scalable delivery.

Operating within a secure and highly regulated environment, the Senior Production Engineerdrivesmanufacturingexcellencethroughrobustprocessdevelopment,disciplined configuration control, and structured risk management. The role champions Design for Manufacture and Assembly (DFMA), strengthens cross-functional collaboration between engineering and operations, and ensures production readiness from prototype through series manufacture.

As a senior technical authority, the role mentors engineering teams, guides continuous improvement initiatives, and leads the development of resilient production solutions for complexelectro-mechanicalsystems,supportingbothprogrammedeliveryandlong-term operational capability.

Key Responsibilities:

• Reporting to the Production Engineering Manager and in his absence the Industrialisation Manager.
• Translate hardware designs into robust, scalable production processes, ensuring manufacturability, repeatability, and compliance with defence standards.
• Develop and optimise production workflows, including tooling, fixtures, assembly methods, and test procedures.
• Lead root cause analysis and corrective actions for production issues, driving continuous improvement and reducing defects.
• Collaborate closely with design engineering to influence early design decisions and ensure alignment with production capability.
• Create and maintain manufacturing documentation, including build instructions, process specifications, PFMEAs, and control plans.
• Support new product introduction (NPI) from prototype through to full rate production.
• Ensure compliance with defence, safety, and quality regulations, including configuration control and traceability requirements.
• Manage production readiness activities, including capability assessments, equipment qualification, and process validation.

• Work with suppliers and internal teams to resolve technical issues and ensure component manufacturability and quality.
• Drive cost effective production solutions without compromising performance, reliability, or security.
• Assist the quality department with inspection and investigation activities.
• Develop and manage CAPEX proposals, including ROI analysis and investment appraisal.
• Perform engineering analysis to reduce test equipment and production assembly equipment downtime and outages.
• Develop best practices to improve production capacity, quality and reliability.
• Stay current with product specifications, engineering technology and production processes.
• Support purchasing with supplier management, process improvement and corrective action.
• Assist with production staff training and the development of workmanship standards in both Mechanical and Electrical teams, identifying areas of improvement.
• Adhere to the company's procedures, policies and goals, always upholding the good reputation of the company.
• Ensure full compliance with health and safety regulations and company policies, always promoting safe working practices and consideration for colleagues.
• Ensure that all procedures are followed as specified in the Quality Manual.

  Skills&Experience Essential

• Degree in Mechanical, Electrical, Manufacturing or Production Engineering (or equivalent experience)
• At least 10+ years’ experience in a defence, aerospace, automotive or other highly regulated environment.
• Demonstrated experience leading NPI activities, including process development, prototyping, and transition to full-rate manufacturing.
• Deep understanding of DFM/DFA principles, with demonstrated ability to embed manufacturability into early-stage design and industrialisation strategy.
• Strong working knowledge of 3D CAD systems, with the ability to interrogate models for DFMA, tolerance analysis, and tooling development.
• Demonstrated experience in the manufacture and integration of complex electro-mechanical systems, including PCB assemblies and precision mechanical components.
• Working knowledge of defence and industry standards (e.g., IPC, MIL-STD) and their application within regulated manufacturing environments.
• Proven capability to lead root cause investigations and implement corrective and preventive actions using structured methodologies (e.g., 8D, DMAIC, 5-Why).
• Experience driving continuous improvement initiatives focused on cost reduction, yield improvement, cycle time optimisation, and process capability enhancement.
• Excellent communication skills and the ability to work cross functionally in a fast paced, regulated environment.

• Experience supporting products through full lifecycle stages, from prototype and low-rate initial production (LRIP) through to full-rate manufacture.

  Desirable

• Experience with automated test systems or production automation.
• Knowledge of configuration management and controlled documentation systems.
• Experience in staff supervision or mentoring.
• Experience supporting audits or regulatory reviews.

  PersonalAttributes

• Demonstrates our company values of Teamwork, Integrity, Excellence and Courage
• Highly organised and methodical approach, with an eye for detail
• The ability to work independently when required
• A flexible, conscientious, and diligent attitude
• Excellent communication, interpersonal and written skills
• A resilient and adaptable approach

  Worklife balance:

• 37.5 hour working week
• Lunchtime finishes on a Friday
• Hybrid / flexible working arrangements
• 28 days annual leave
• Christmas closure
• Holiday purchasing scheme

  Benefits:

• Group pension plan – matched contributions up to 5%
• Income protection scheme
• Employee Assistance Programme gives you and your family access to 4 key services including remote GP service, second opinion, mental health pathway service and physiotherapy consultations
• Life assurance policy, including bereavement counselling and probate helpline
• Company shares incentive plan and save as you earn scheme
• Electric vehicle salary sacrifice scheme
• Wellbeing initiatives, including access to wellbeing app and the addition of mental health support for all employees. Plus, regular activities across our sites to support and promote wellbeing
• Regular sports and social activities
• Gym membership discounts
• Reward platform (high street discounts, employee benefits, health, and wellbeing offerings).
• Recruitment referral bonus scheme
• Excellent learning & development opportunities
• Great working environment with free, onsite car parking across all our locations

SecurityClearanceRequirements:

Due to the nature of our business, our staff need to be able to obtain UK Security Clearance as a mandated requirement. Therefore, if successful, you will need to provide proof of identity, employmenthistory andrighttoworkintheUK,alongwithproofofUKresidencyforatleastfive years.