Manufacturing Engineer

Aalto; Farnborough; On-site; GBP 55,000 - 85,000; Full time

Benefits offered by this job

25 days holiday

Private medical insurance

Dental and optical cashback

Pension plan

Income protection

Life assurance

Salary sacrifice car scheme

Perkbox discounts

Employee assistance programme

Job summary

AALTO in Farnborough designs and builds Zephyr UAV platforms, shaping the future of stratospace. As a key Manufacturing Engineer you will translate design intent into production reality, driving lean processes, MRP routings and shop-floor SOPs to deliver safe, reliable, cost-efficient outcomes.

You’ll collaborate across functions, manage shop floor requirements and contribute to continuous improvement while upholding health, safety and quality in a highly regulated environment.

Qualifications

• Experience in highly regulated industries.
• Experience in avionics assembly, integration and test.
• Composite structure assembly experience.
• Experience creating assembly process instructions.
• Experience creating ERP routings.
• Experience RCCA methods (Fishbone, 5 Whys, 8D).
• Ability to work independently and within a team.
• Excellent communication skills.

Responsibilities

• Design and qualification of a HAPS production system using Manufacturing System Engineering tools and processes.
• Collaborating with Facilities Management to deliver shop floor requirements.
• Create/change MRP shop floor routings / job cards / SOPs / quality care cards.
• Support procurement, supply chain monitoring and Make v Buy decisions.
• Provide technical problem solving and support to production and supply chain.
• Apply APQP as appropriate.
• Perform DFM / DTC studies and input to design teams.
• Collaborate with Ground Service Equipment and Jig & Tools suppliers.

Skills

Excellent communication

Independent worker

Team collaboration

Problem solving

Tools

ERP routings

MRP system

RCCA methodology

Job description

Location: Farnborough

Contract Type: Full Time, Permanent

Hours: 37

AALTO, a global leader in Stratospace. Based in Farnborough, AALTO is an Airbus subsidiary that manufactures, operates, and delivers services with its solar-powered, stratospheric platform: Zephyr.

Zephyr’s persistence enables continuous flight for months at a time. Its current flight-time record of over 67 days in the stratosphere. From above 60,000+ft, or 20km above ground, AALTO can deliver several applications including direct-to-device connectivity and high-resolution Earth observation.

AALTO operates in a new operational layer between most of air traffic and low-Earth orbit, Stratospace. This is where high-altitude platforms led by Zephyr deliver services to commercial and government partners. We can help monitor environments, observe borders, track natural disasters and connect unconnected communities.

Join us as we create a new domain of aerospace: Stratospace. You’ll be part of a highly-skilled, innovative and passionate group of people – Team AALTO. Together, we can Unlock Stratospace.

About The Role

As a key member of the Manufacturing Engineering Team, your main tasks and responsibilities will be to provide hands‑on enablement of design intent into a production system for HAPS Zephyr UAV’s platforms to Safety, Quality, Cost and Time.

You will collaborate with different skillsets and departments throughout AALTO to help propel Zephyr to stratospheric heights.

Responsibilities to include:

• Design and qualification of a HAPS production system using Manufacturing System Engineering tools and processes. (Cellular production approach, Lean Process flow, line balancing, capital investment items, factory layout & simulation).
• Collaborating with the Facilities Management team to deliver shop floor requirements.
• Create/change MRP system shop floor routings / job card definitions / shop floor standard operating instructions (SOI’s) / quality care cards
• Technical dossiers and support to procurement activities, supply chain monitoring and Make v Buy decisions.
• Technical problem solving and support to production and supply chain.
• Application of APQP as appropriate.
• Perform Design For Manufacture (DFM) / Design To Cost (DTC) studies and provide input to design teams
• Collaboration with Manufacturers of Ground Service Equipment and Jig & Tools for design, manufacture, calibration & maintenance.

You will also be responsible for:

• Deriving and enabling production KPI’s in conjunction with operations teams.
• Continuous Improvement of the production system in line with business targets
• Enable Health and Safety target achievement.
• Enablement of the “Right First Time” Quality culture with associated business systems and feedback loops

Skills and Knowledge Required

Experience within highly regulated industries

Experience in one or more of the following areas:

• Avionics
• Assembly, Integration, and Test
• Composite structure assembly

• Experience creating assembly process instructions.
• Experience creating ERP routings.
• Experience using RCCA methodology such as Fishbone, 5 Whys and 8D.
• Ability to work independently and within a team.
• Excellent communication skills.

In addition to an attractive market-aligned salary, we offer:

• Rewarding Excellence: Benefit from our short-term incentive plan that rewards your hard work and dedication.
• Enjoy Your Time Off: Benefit from 25 days of holiday to relax and recharge.
• Stay Healthy: We’ve got your health covered with private medical insurance, along with dental and optical cash back.
• Secure Your Future: Take advantage of our personal pension plan to ensure a comfortable retirement.
• Peace of Mind: Our income protection and life assurance schemes are there to support you when you need it most.
• Getting around: Drive the latest vehicles with our discounted salary sacrifice scheme.
• We Care About You: Our employee assistance programme is always available to provide the support you need.
• Perks Galore: Enjoy a range of employee discounts via Perkbox, from household goods to travel!