Senior Manufacturing Engineer

Expleo is a trusted partner for end-to-end, integrated engineering, quality services and management consulting for digital transformation.  We help businesses harness unrelenting technological change to successfully deliver innovations that will help them gain a competitive advantage and improve the everyday lives of people around the globe.

We have several exciting on-going projects with clients across both commercial & naval marine domains and are seeking to expand our existing Marine Engineering capability.

As a Senior Gear Manufacturing Engineer, every day at Expleo presents new opportunities to drive operational excellence and support the delivery of innovative engineering solutions. Working in a dynamic environment, you will respond to evolving technologies, production challenges, and customer requirements while contributing to the optimisation of manufacturing processes and systems. You will play a key role in the industrialisation of new products, process development and improvement, implementation of innovative manufacturing tools and techniques, and the delivery of engineering support across a diverse range of programmes. The role also offers the opportunity to contribute to sustainability initiatives, advanced manufacturing technologies, and continuous improvement activities that enhance quality, efficiency, and productivity across the business.

• →To be/ become the Subject Matter Expert (SME) for gear profile generation (hobbing, shaping, and profile grinding) and finish grinding (journals & cones/ thrust faces), liaising between the Design Engineering team and the machine tool operators. 
• →Provide technical leadership and hands-on problem-solving support to manufacturing and assembly teams, ensuring products are built to the required quality standards and delivered in accordance with programme schedules.
• →Act as the primary interface between Engineering and Manufacturing, ensuring technical requirements, design intent, and production challenges are communicated effectively and resolved in a timely manner.
• →Develop and maintain Subject Matter Expert (SME) knowledge in gear manufacturing processes, including hobbing, shaping, profile grinding, and finish grinding of journals, cones, and thrust faces, providing technical guidance to both Design Engineering and machine shop personnel.
• →Assess component manufacturability and manufacturing process capability to support a right-first-time approach, while actively contributing manufacturing expertise during design reviews and product development activities.
• →Lead Process Failure Mode and Effects Analysis (PFMEA) activities, including process mapping, risk assessment, mitigation planning, and the development and approval of manufacturing procedures and control protocols.
• →Interpret engineering drawings and specifications, producing and approving manufacturing drawings and supporting documentation to facilitate efficient production.
• →Ensure manufacturing plans, processes, and documentation fully incorporate Quality Assurance requirements and support compliance with internal and customer standards.
• →Drive continuous improvement initiatives focused on enhancing product quality, reducing cycle times, improving productivity, and increasing process capability.
• →Develop bespoke manufacturing methods, tooling, fixtures, and process solutions, ensuring compliance with Machinery Safety Regulations and safe working practices.
• →Work collaboratively with cross-functional teams including Manufacturing, Design Engineering, Quality, Supply Chain, and external stakeholders such as suppliers and auditors to achieve programme objectives.
• →Create and maintain work orders, technical packs, routings, operation sheets, and manufacturing instructions to support effective production planning and execution.
• →Apply a strong understanding of heat treatment processes and their impact on material properties, dimensional stability, manufacturing methods, and final product performance.

• Degree qualified in a relevant STEM discipline (e.g.,Mechanical Engineering, Marine Engineering), or equivalent experience.
• Professional member of a relevant engineering institution (e.g., IMechE, IMarEST, IMechE, IET).

• Deep understanding of manufacturing processes associated with rotating components, including turning, boring, milling, and other precision machining operations.
• Good knowledge of engineering principles, manufacturing techniques, and business systems used to support production and operational activities.
• Strong understanding of dimensional inspection methods, measurement systems, and metrology principles to ensure product conformity and quality.
• Ability to interpret complex engineering drawings and specifications, and generate or approve manufacturing-stage drawings and associated documentation.
• Comprehensive knowledge of Geometric Dimensioning and Tolerancing (GD&T) and its application in manufacturing and inspection processes.
• Comprehensive knowledge of SAP and its application within a manufacturing engineering environment, including production routings, work orders, Bills of Materials (BOMs), and engineering change control.
• Proficient in the use of 2D and 3D CAD software to develop manufacturing layouts, tooling concepts, technical documentation, and engineering records.
• Chartered member of a relevant engineering institution (e.g., IMechE, IMarEST, IMechE, IET)

• Experience within a heavily regulated industry e.g. Marine, Aerospace, Defence etc.
• Experience in CNC programming, machining practices, and process optimisation to support efficient and repeatable manufacturing operations.