Process Engineer – Lean, DFMA & Continuous Improvement

Gapp Search; Droitwich Spa; On-site; GBP 35,000 - 39,000; Full time

Job summary

Gapp Search is recruiting three Process Engineers for an on-site role in Droitwich Spa. You will design and enhance manufacturing process flows, standardise work, and drive continuous improvement in a low-volume, high-value environment.

You'll analyse workflows, develop SOPs and control plans, and apply PFMEA/DFMA to improve manufacturability. Collaboration with Design, Quality, Production and Supply Chain will be essential to cost, quality and delivery optimization.

Qualifications

• Strong experience in manufacturing engineering, process engineering or a similar role, ideally within process plant, HVAC, modular build or engineered products.
• Strong knowledge of DFMA, PFMEA, control plans, process standardisation and continuous improvement.
• Experience designing manufacturing process flows and production layouts.
• Good understanding of manufacturing processes, materials and trade disciplines within a practical production environment.
• Experience developing SOPs, work instructions, visual standards and training materials.
• Practical experience with NCR management and structured corrective-action methods.

Responsibilities

• Design and implement improved manufacturing process flows and production layouts to increase efficiency.
• Analyse production workflows to identify standardisation and continuous improvement opportunities.
• Develop and maintain standardised work instructions, SOPs, visual standards, control plans and process flow diagrams.
• Conduct PFMEAs and use DFMA principles to improve manufacturability and assembly efficiency.
• Manage NCRs and drive corrective and preventive actions through structured problem-solving.
• Implement Lean methodologies and modular build strategies to improve production flow, quality and consistency.
• Maintain accurate records of process changes within BOM structures and routing systems, ensuring full traceability.
• Support production teams with practical process improvements, training and best-practice guidance.
• Ensure manufacturing processes comply with health, safety and environmental requirements.
• Work closely with Design, Quality, Production and Supply Chain to improve quality, cost and delivery performance.

Skills

DFMA

PFMEA

Control plans

Process standardisation

Continuous improvement

Lean manufacturing

Job description

Gapp Search is recruiting three Process Engineers for an on-site role in Droitwich Spa. You will design and enhance manufacturing process flows, standardise work, and drive continuous improvement in a low-volume, high-value environment.

You'll analyse workflows, develop SOPs and control plans, and apply PFMEA/DFMA to improve manufacturability. Collaboration with Design, Quality, Production and Supply Chain will be essential to cost, quality and delivery optimization.