Manufacturing Engineer

Syos Aerospace; Fareham; Hybrid; GBP 42,000 - 65,000; Full time

Job summary

SYOS Aerospace designs and manufactures autonomous systems for air, land, sea and subsurface applications, turning engineering concepts into mass‑production hardware. As a Manufacturing Engineer, you’ll translate designs into practical production flows, develop PFMEA and APQP controls, and create work instructions with the right tooling.

You’ll lead trial builds, optimize processes on the production floor and collaborate across Engineering, Quality and Supply Chain to enable scalable

Qualifications

• Experience in manufacturing engineering within an assembly or production environment.
• Experience creating process flows, manufacturing documentation and work instructions from the ground up.
• Proven PFMEA authoring experience and understanding how they inform production controls.
• Experience planning, running and closing out production trial runs, pilot builds or new line introductions.
• Hands-on process experience in wire harness, composite structures, or engine assembly.
• Experience specifying tooling, fixtures and production equipment.
• Familiarity with ERP/MRP systems, BOMs, routings and work orders.
• Understanding of APQP principles, such as EN/AS 9145, AIAG or equivalent.
• Strong problem-solving skills and the ability to work collaboratively across Engineering, Quality, Supply Chain and Production.
• Willingness to spend significant time on the production floor.
• Ability to meet BPSS requirements.

Responsibilities

• Translate engineering designs and NPI handover packages into production-ready process flows, assembly sequences, workstation layouts and manufacturing documentation.
• Develop and maintain PFMEA, applying APQP principles to identify risks and ensure appropriate controls are in place.
• Develop clear, practical work instructions and specify the tooling, fixtures and test equipment required for efficient and consistent production.
• Plan and run trial builds, capture cycle times, resolve issues and update manufacturing processes before serial production begins.
• Work with Quality to qualify special processes, establish operator approval requirements and develop practical build competency.
• Assess the impact of design changes, support internal PPAP requirements and ensure manufacturing documentation, tooling and processes remain aligned with released engineering designs.
• Drive continuous improvement through takt time and line balancing, bottleneck reduction, error-proofing, scrap and rework reduction, and the transfer of work into in-house production cells.

Skills

Process engineering

PFMEA

APQP

NPI handover

Work instructions

Takt time

Line balancing

Problem solving

On-floor presence

Education

Engineering degree

Manufacturing engineering qualification

Job description

Build the Future of Autonomous Systems

SYOS designs and manufactures advanced uncrewed systems across air, land, sea and subsurface. We combine intelligent engineering, AI-driven autonomy and innovative design to create next-generation vehicles operating in some of the world's most challenging environments. Our mission is to extend human capability, protect people and deliver operational advantage through accessible, scalable and intelligent autonomous technology.

About the role

As Manufacturing Engineer, you'll turn engineering designs and New Product Introduction (NPI) handover packages into practical, efficient production processes across a range of in-house manufacturing cells. These include wire harness manufacture, composite structures, electronics, engine and fuel system assembly and testing, and final integration.

You’ll take ownership of manufacturing processes from initial work instructions and tooling requirements through to production trial runs and ramp‑up, working closely with Engineering, Quality, Supply Chain and Production to ensure processes are safe, repeatable and ready for serial production.

What you’ll be doing

• Translate engineering designs and NPI handover packages into production‑ready process flows, assembly sequences, workstation layouts and manufacturing documentation.
• Develop and maintain Process Failure Mode and Effects Analysis (PFMEA), applying APQP principles to identify risks and ensure appropriate controls are in place.
• Develop clear, practical work instructions and specify the tooling, fixtures and test equipment required for efficient and consistent production.
• Plan and run trial builds, capture cycle times, resolve issues and update manufacturing processes before serial production begins.
• Work with Quality to qualify special processes, establish operator approval requirements and develop practical build competency.
• Assess the impact of design changes, support internal PPAP requirements and ensure manufacturing documentation, tooling and processes remain aligned with released engineering designs.
• Drive continuous improvement through takt time and line balancing, bottleneck reduction, error‑proofing, scrap and rework reduction, and the transfer of work into in‑house production cells.

What we’re looking for

We’re looking for a Manufacturing Engineer who combines strong process engineering skills with a practical, hands‑on approach to production. You’ll ideally have:

• Manufacturing engineering experience within an assembly or production environment.
• Experience developing process flows, manufacturing documentation and work instructions from the ground up.
• Proven experience authoring and maintaining PFMEAs, understanding how they inform production controls and Control Plans.
• Experience planning, running and closing out production trial runs, pilot builds or new production line introductions.
• Hands‑on process experience in at least one of the following areas: wire harness manufacture, composite structures, or engine and complex mechanical assembly.
• Experience specifying tooling, fixtures and production equipment.
• Familiarity with ERP or MRP systems, including manufacturing bills of materials (BOMs), routings and work orders.
• Understanding of APQP principles, such as EN/AS 9145, AIAG or equivalent.
• Strong problem‑solving skills and the ability to work collaboratively across Engineering, Quality, Supply Chain and Production.
• A practical mindset and willingness to spend significant time on the production floor.
• Ability to meet Baseline Personnel Security Standard (BPSS) requirements.

It would be advantageous if you also have:

• Aerospace, defence or uncrewed systems manufacturing experience.
• Wire harness crimp process certification, die qualification and pull testing.
• Composite layup, bonding or cure process experience.
• Engine assembly and testing experience.
• Lean manufacturing experience, including takt time, line balancing, 5S and error‑proofing.
• Design for Manufacture and Assembly (DFM/DFA) review experience.
• Familiarity with AS9100.
• An engineering degree or formal manufacturing engineering qualification.

Why join SYOS?

This is an opportunity to help establish manufacturing processes and production capability at a growing UK facility, playing a key role in bringing next‑generation autonomous systems from design into production.

You’ll work closely with engineers, production specialists and quality professionals to solve real‑world manufacturing challenges, improve build processes and help scale production as the business grows.

At SYOS, we value collaboration, integrity, delivery and continuous improvement. We want people who take ownership, challenge existing processes and turn engineering ideas into practical, reliable solutions.

If you’re a hands‑on Manufacturing Engineer who enjoys building production processes, solving technical challenges and seeing the direct impact of your work, we’d love to hear from you.