Senior Industrial Process Engineer

Thales; Crawley; On-site; GBP 125,000 - 150,000; Full time

Job summary

A leading technology company in Crawley is seeking a Senior Industrial Process Engineer to oversee late-stage industrialization for new products. This full-time, onsite role focuses on optimizing manufacturing processes, ensuring compliance with safety standards, and driving continuous improvement. The ideal candidate will have relevant engineering experience, strong understanding of lean principles, and excellent relationship-building skills. The position also requires UK National security clearance, due to the sensitive nature of the work.

Benefits

Annual bonus (VCP)

Pension matching up to 7%

Life Assurance – 2× base salary

Private Medical Insurance

Flexible benefits and discounts

Qualifications

• Proven relevant experience in a similar role.
• Experience of establishing new products in industrial manufacturing.
• Strong understanding of lean principles and continuous improvement.

Responsibilities

• Lead and own the late‑stage industrialisation process.
• Support earlier industrialisation phases with Industrial Architects.
• Drive continuous improvement through various methodologies.

Skills

Lean principles

Design for Manufacture (DFM)

Design for Assembly (DFA)

Proven presence and credibility

Data presentation skills

Education

HNC or HND in relevant discipline

Job description

Senior Industrial Process Engineer

Location: Crawley, United Kingdom – Full‑time (5 days/week) onsite.

What the role has to offer

• End‑to‑end influence: Ownership from late‑stage industrialisation through to steady‑state production, shaping how new products are manufactured.
• High‑impact environment: Work within a multidisciplinary industrial engineering function (IPEs, Architects, Cost Engineers) on complex, high‑reliability defence products.
• Continuous improvement & innovation focus: Opportunity to embed Industry 4.0, lean methodologies, and advanced manufacturing practices across the shopfloor.

Our Opportunity

Reporting to the Manufacturing Engineering Manager and working within the Industrial Engineering function, this role leads the late stages of industrialisation and supports the production of released products while driving continuous improvement. As a Senior Industrial Process Engineer, you will deliver the industrial capability for new products, support existing ones, and lead MRL 6–8 activities, ensuring compliance with MRL, APQP and safety standards. You’ll optimise shopfloor processes through data‑driven improvements, contribute to earlier industrialisation phases, identify Industry 4.0 opportunities, and mentor the wider IPE team.

Key Responsibilities and Tasks

• Lead and own the late‑stage industrialisation process (MRL 6–8), ensuring products are ready for full‑scale manufacture.
• Support earlier industrialisation phases in collaboration with the Industrial Architect.
• Set best‑practice standards and provide technical leadership across the Industrial Engineering team.
• Provide ongoing IPE support for production post‑launch (MRL 8+), resolving issues and optimising flow.
• Drive continuous improvement through VSM, 5S, TPM, PFMEA, control plans, and InCIght methodologies.
• Develop and optimise production processes, including BOMs, routings, MES routes, ERP setup, and MI creation.
• Ensure compliance with all health, safety, environmental and regulatory requirements across manufacturing processes.
• Identify and implement Industry 4.0 opportunities to enhance capability, efficiency, and data‑driven decision‑making.

About You

• Proven relevant experience in a similar role and/or transferable skills.
• Background in industrial engineering, manufacturing engineering or process engineering.
• Experience of establishing new products into an industrial manufacturing environment.
• HNC or HND in a relevant discipline, an engineering apprenticeship, or equivalent proven experience.
• Strong understanding of lean principles and continuous improvement.
• Skilled in Design for Manufacture (DFM) and Design for Assembly (DFA).
• Proven ability to convey information clearly, confidently and appropriately to different audiences.
• Demonstrated experience of working across departments, building strong relationships and ensuring alignment.
• Proven presence, credibility and the ability to influence decisions and stakeholders constructively.
• Experienced in presenting data, updates and recommendations in a structured, concise and easily understood manner.
• Proven structured reasoning and sound judgement abilities.
• Experienced in driving progress for both team and project objectives, ensuring milestones are met.

What We Offer You

• Annual bonus (VCP).
• Pension – match like‑for‑like up to 7% of annual base salary.
• Life Assurance – 2 × base salary minimum (8 × salary if part of the pension scheme).
• Income Protection – 50% of salary less state benefits for 5 years.
• Annual Leave – 201 hours, bank holidays, plus 1 company day.
• Private Medical Insurance – Couples cover.
• 4‑day working week – 9.25 hours per day.
• 24/7 Employee Assistance Programme.
• 24 hours paid leave for volunteering activities.
• Access to flexible benefits and discounts – dental insurance, buying & selling annual leave, cycle to work, and many more.

UKEO (UK Eyes Only)

Due to the nature of the work that we do at Thales, many of our roles are subject to security restrictions. This role requires you to be a UK National and achieve Security Clearance (SC) without any caveats. It would be advantageous if currently held; otherwise, the successful applicant must undergo, achieve, and maintain SC Clearance prior to commencing employment. If approved by the MOD, a dual national from a non‑ITAR country may be considered.

To be eligible for full SC, you generally need to have resided in the UK for the last 5 years. In some circumstances, a minimum of 3 years’ residence in the UK over the last 5 years may be accepted, with additional overseas checks.

Equal Opportunity

At Thales, we are committed to equal opportunities and welcome all talented individuals to consider joining our team. If you don’t match every statement below but feel you have some of the experience, knowledge or skills needed for this role, we encourage you to apply.

Next Steps

Great journeys start here – apply now!