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Senior Project and Design Engineer

2 months ago


Newport, Newport, United Kingdom EnerSys Delaware Inc. Full time

About EnerSys Delaware Inc.

EnerSys Delaware Inc. is a leading global provider of stored energy solutions for industrial applications. With over thirty manufacturing and assembly plants worldwide, we serve over 10,000 customers in more than 100 countries.

Job Purpose

We are seeking a highly skilled Senior Project and Design Engineer to join our team. The successful candidate will work closely with Process Engineering, Technical, Production, Product Design, and Quality teams to ensure seamless project execution and product transition from design to production.

Key Responsibilities

  • Project Management
    • 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 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.
    • Supports development of associated documentation and estimates of manufacturing cost.
    • Contribute as a key member of strategic to 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.
  • Technical Expertise
    • Develop technical specifications for new manufacturing systems and machinery and write invitation to tender documents.
    • Compile detailed cost estimates and agree budgets with engineering manager for capital request.
    • Advise and coordinate with the technical and process engineering team on any new equipment, tooling, process design, process changes/modifications etc 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.
    • Required to make decisions within remit above and to 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 managing other engineers and technicians and reviewing the technical aspect of assigned projects task 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 assemble 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 modelling 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 Sixsigma Blackbelt or Green Belt qualified.