Lead Process Engineer – Design Phase (Methods, Integration, Test & Deployment)

Thales; Bendigo; On-site; AUD 120,000 - 180,000; Full time

Benefits offered by this job

Family friendly workplace

PPE provided and tooling

Fitness Passport discount

Employee discounts

Parental leave

Veterans leave

Training & growth opportunities

Job summary

Thales is seeking a Lead Process Engineer – Design Phase for our Bendigo site. You will define, develop, and optimise process-engineering strategies during the design and early industrialisation phases to ensure robust, scalable production-ready solutions.

Working with the Product Architect and Industrialisation Manager, you will validate industrial requirements, translate design intent into documentation, tooling, and processes, and guide early cost modelling for efficient manufacturing and

Qualifications

• Strong knowledge of design for manufacture, design for repair, and design for test principles.
• Extensive understanding of production and repair processes, with the ability to influence design decisions early.
• Experience in industrial management control, cost modelling, and early phase planning.

Responsibilities

• Establishing design-phase manufacturing, repair, service, testing, and integration strategies.
• Defining and preparing design-phase process documentation, including ranges and tooling concepts.
• Validating manufacturability, testability, serviceability, and integration constraints with engineering teams.

Skills

DfM (design for manufacture)

DfR (design for repair)

DfT (design for test)

Lean methods

Industrialisation

Leadership/leadership

Job description

At Thales, we know technology has the ability to make our world more secure, sustainable, and inclusive – and that it’s all driven by human intelligence.

Because it takes human intelligence to build and power the systems and solutions that people depend on every day. So we stay curious and make space for diverse points of view. We share what we know and we challenge what’s possible.

From manufacturing and engineering to cybersecurity and space, we’re driving progress in some of the world’s most important industries – and working together to build a future we can all trust.

Our Benefits

• Family Friendly Workplace Certified company with Competitive Remuneration.
• Be a part of a world-class workshop with all tooling and PPE provided.
• Fitness Passport Discount + Employee discounts with a number of affiliates (Travel, Car hire, Tech, Medical Insurance).
• Modernised Paid Parental Leave.
• Veterans Leave.
• Personal & professional training, development and internal growth opportunities.

Our Team

As part of our VTS business, our PRV team is primarily focused on the design, manufacture, delivery and support of protected mobility vehicles on a global scale. We are very proud of everything we do in support of both the Bushmaster and Hawkei platforms as we all work together towards our purpose. Most importantly – be a part of a positive team culture that is focused on our people.

Your Role:

Come join our growing Industry team as a Lead Process Engineer – Design Phase. In this role, you will be responsible for defining, developing, and optimising process‑engineering strategies and solutions during the design and early industrialisation phases. Working in close collaboration with the Product Architect and the Process Engineering Manager – Industrialisation, the role ensures that all design‑phase industrial requirements are understood, validated, and translated into robust, scalable processes that support reliable production, testing, integration, and sustainment of Thales products and systems.

This position requires strong leadership behaviours aligned with the Lead@Thales Framework, ensuring innovation, agility, collaboration, and long‑term industrial excellence.

Working at our Bendigo site, on Dja Dja Wurrung Land, your exciting new career opportunity will see you:

• Establishing design‑phase manufacturing, repair, service, testing, and integration strategies, ensuring industrial requirements are embedded early.
• Defining and preparing design‑phase process documentation, including preliminary ranges, tooling concepts, test strategies, and integration plans.
• Validating manufacturability, testability, serviceability, and integration constraints with engineering teams to ensure industrial feasibility.
• Collaborating with R&D engineering to translate design intent into clear industrial requirements and early alignment on documentation, tooling, and process needs.
• Developing early test and control strategies for equipment and subassemblies, ensuring industrial test requirements are captured prior to design freeze.
• Design Readiness Reviews — Lead and contribute to design readiness gates (PDR, CDR, MDR), ensuring industrial requirements are validated before design freeze.
• Providing early technical guidance to APRU and production teams to ensure design decisions support takt time, flow, and industrial constraints.
• Driving continuous improvement and innovation in design‑phase processes to reduce cost, cycle time, and complexity.
• Contributing to early cost modelling and ensuring objective cost estimates are developed and maintained throughout the design phase.

Your Experience:

• Strong knowledge of design for manufacture, design for repair, and design for test principles.
• Extensive understanding of production and repair processes, with the ability to influence design decisions early.
• Experience in industrial management control, cost modelling, and early phase planning.
• Familiarity with Lean methodologies (flow management, Gemba, PDCA, TPM) applied during design and industrialisation.
• Strong analytical and problem solving capability, particularly in early phase feasibility assessments.
• Knowledge of industrial IT systems, dashboards, and decision support tools.
• Ability to influence engineering teams and ensure industrial constraints are understood and respected.
• Strong communication skills with the ability to mobilise resources, share information transparently, and build long term commitment across teams.
• Demonstrated agility, adaptability, and a continuous improvement mindset.
• Understanding of HSE principles, risk management, and safe design practices.

As a Defence security clearance is required for this role, applicants must be Australian citizens and eligible to obtain and maintain an appropriate clearance. To learn more about clearances please visit http://www.defence.gov.au/AGSVA/

It’s easy to dismiss the perfect opportunity if you don’t see yourself as the perfect fit. If this role feels right – no matter your background or personal circumstances – please introduce yourself or join our community. We’re committed to supporting a diverse workplace, and that starts here.

We’re proud to be endorsed by WORK180 as an Employer for All Women, but we know there’s always more we can do. We’ll continue to foster industry partnerships, employee resource groups (ERGs) and development opportunities to make Thales a genuinely equitable employer, for everyone.