Manufacturing Engineer

Full-time / London / On-site

IONATE is a deep tech scale-up building the hardware and software backbone for smart grids. Our mission is to transform power systems - from grids and microgrids to renewables and data centres - unlocking the massive potential in this under-innovated sector that touches every aspect of our modern lives.

We are now looking for a Manufacturing Engineer to join our Operations team. You will carry out the detailed manufacturing engineering work needed to move the Hybrid Intelligent Transformer (HIT) from engineering builds into safe, repeatable manufacture at our internal facility in London and through contract manufacturing partners. Working with Engineering, Industrialisation and Production Test Teams you will develop and prove manufacturing processes, tooling, assembly documentation and shop-floor controls for low-volume production and future scale-up.

This is a genuinely hands-on role. You will spend your time in the build and test areas, working directly with our hardware engineers and the Lead Industrialisation Engineer to resolve problems at the point of use. You will turn build learning into practical manufacturing improvements, raise product-change requirements through Engineering and implement approved changes in production.

Requirements

What you will do:

• Carry out hands-on build support. Support the assembly, integration and investigation of early units on the shop floor. Observe how the product is actually built, identify practical problems and convert learning into improved processes, tooling and documentation.
• Develop manufacturing processes. Develop and improve manufacturing routes, build sequences, work-cell methods, standard labour assumptions, material presentation and safe working practices for repeatable low-volume production.
• Prepare manufacturing documentation. Create and maintain manufacturing bills of materials, routings, work instructions, process specifications, critical settings, visual standards, build records and operator training materials. Incorporate approved inspection and test points into the build process.
• Develop and prove tooling and fixtures. Specify, develop, build or commission assembly jigs, fixtures, benches, handling aids and line-side equipment. Trial them with technicians, incorporate feedback and provide evidence that they are safe, capable and maintainable.
• Develop manufacturability improvements. Use evidence from real builds to develop practical DFM and DFA proposals with Engineering and Operations. Quantify the expected benefits and provide the evidence needed to progress required product changes through the engineering change process. Update manufacturing processes, tooling and documentation after approval.
• Support process quality and validation. Provide manufacturing-process input to process FMEA and control plans. Carry out assigned process validation and capability studies, investigate build defects at source and implement approved corrective actions within the manufacturing process.
• Implement configuration and effectivity changes. Maintain accurate as-built records and apply approved product and process changes at the defined serial number, lot, date or build stage, with no uncontrolled shop-floor changes.
• Measure and improve manufacturing performance. Collect and analyse cycle time, labour hours, first-pass yield, defects and rework. Use the data to balance work, remove waste, improve ergonomics and implement improvements against agreed industrialisation priorities.
• Support manufacturing-process transfer. Prepare manufacturing processes, assembly documentation, tooling and operator training for transfer to contract manufacturers. Support process trials and pilot builds, resolve assigned issues and provide readiness evidence to the Lead Industrialisation Engineer.

What you will need:

• Relevant technical foundation. A degree, apprenticeship or equivalent practical experience in manufacturing, mechanical, electrical, mechatronic or production engineering, together with clear communication skills and the flexibility to support UK suppliers and manufacturing partners when required.
• A genuine preference for hands-on work. You enjoy working directly with products, tools, fixtures, technicians and engineers. You are comfortable assembling, measuring, modifying, troubleshooting and proving solutions in the build area rather than managing the work only through meetings and spreadsheets.
• Relevant manufacturing experience. Practical experience supporting the manufacture or industrialisation of complex electromechanical, electrical, power-electronic or similarly demanding hardware.
• Production documentation capability. The ability to create clear bills of materials, routings, work instructions, process specifications, visual standards, build records and training materials that people can use successfully at the point of work.
• Tooling and process development. Experience developing or commissioning practical jigs, fixtures, workstations and process controls, then proving them through use, measurement and operator feedback.
• Manufacturing methods. Working knowledge of DFM and DFA, process FMEA, control plans, process validation, production-readiness reviews and basic capability improvement.
• Structured problem solving. The ability to investigate build and process problems at source, use data and root-cause methods, implement corrective actions and confirm that the solution has worked.
• Configuration discipline. Experience working with controlled bills of materials, drawings, deviations, engineering changes, as-built records and product or process effectivity within an ERP, PLM or equivalent environment.

It would be useful to have:

• Power-sector product experience. Manufacturing experience involving power electronics, high-voltage equipment, transformers, energy infrastructure or another safety-critical product environment.
• Prototype and low-volume production. Experience supporting products as they move from engineering builds into repeatable low-volume manufacture while the design and process are still maturing.
• High-complexity production-build experience. Practical experience supporting low-volume, high-complexity electromechanical or power-electronic builds, including the development, installation, commissioning and improvement of the production equipment, tooling and processes required.
• Practical design capability. Experience using CAD or equivalent tools to develop fixtures, handling aids, workstation layouts or simple production equipment, supported by practical workshop skills.
• CEM transfer experience. Experience supporting process transfer, training and pilot builds at a contract manufacturer or key supplier.
• Test and continuous improvement. Experience with production test fixtures, traceability tools, Lean, statistical process control or other practical methods for improving flow, quality and repeatability.

Benefits

• Employee Option Plan: You get equity in IONATE, so as we succeed so do you.
• Private Medical & Dental Insurance: From day one, we provide you with full, comprehensive private medical and dental cover through Bupa. You also have the option to add any dependents to your cover. Please ask us for more details.
• Company pension: a flexible, and sustainable pension product to help you plan for your future.
• Career Development: It’s important to us that you have the opportunity for ongoing professional development and career growth. You will receive an annual budget for professional development and work with your team to set and reach goals every year.
• Flexible working schedules: You will have the flexibility for occasional work-from-home arrangements. Talk to us at the application stage about this.
• Cycle to Work Scheme: Low carbon travel is important for everyone, so we have in place a cycle scheme to help you purchase a bicycle.
• Slow travel: We believe in a low carbon future, so if you wish to travel by a lower carbon method – but it takes much longer than flying - we will give you an extra 2 slow travel days per year.