Senior Manufacturing Engineer

Expleo Group; Huddersfield; On-site; GBP 65,000 - 85,000; Full time

Benefits offered by this job

ExpleoAcademy

Competitive benefits

Collaborative environment

Job summary

Expleo Group in the United Kingdom seeks a Senior Gear Manufacturing Engineer to drive manufacturing excellence for marine and defence programmes. You will act as SME for gear processes and lead PFMEA activities.

You will collaborate with Design Engineering, quality, and suppliers, interpret drawings, maintain manufacturing documentation, and push continuous improvement across tooling, processes and compliance with safety regulations.

Qualifications

• Degree in Mechanical or Marine Engineering or equivalent.
• Member of a relevant engineering institution (IMechE/IMarEST/IET).
• Experience in regulated marine/defence environments and CNC programming.

Responsibilities

• Serve as SME for gear generation (hobbing, shaping, profile grinding) and finish grinding.
• Provide technical leadership to manufacturing and assembly teams to meet quality Standards.
• Interface between Engineering and Manufacturing to resolve production challenges.
• Develop SME knowledge in gear processes and guide shop personnel.
• Assess manufacturability and process capability to support first‑time right.
• Lead PFMEA activities including process mapping and mitigation planning.
• Interpret drawings to approve manufacturing documentation.
• Ensure QA requirements are embedded in plans and procedures.
• Drive continuous improvement to reduce cycle times and boost productivity.
• Develop tooling, fixtures, and manufacturing methods with safety compliance.
• Collaborate with cross‑functional teams and suppliers to meet programme objectives.
• Create work orders, routings, and manufacturing instructions.

Skills

Gear manufacturing

Hobbing

Shaping

Profile grinding

Finish grinding

PFMEA

GD&T

SAP

CNC programming

Metrology

CAD (2D/3D)

Marine/Defence experience

Education

BEng/MEng in Mechanical/Marine Engineering

Professional engineering institution membership (IMechE/IMarEST/IET)

Tools

2D/3D CAD software

Process simulation

Milling/Turning machinery

Job description

Overview

Expleo is a trusted partner for end-to-end, integrated engineering, quality services and management consulting for digital transformation. We help businesses harness unrelenting technological change to successfully deliver innovations that will help them gain a competitive advantage and improve the everyday lives of people around the globe.

We have several exciting on-going projects with clients across both commercial & naval marine domains and are seeking to expand our existing Marine Engineering capability.

As a Senior Gear Manufacturing Engineer, every day at Expleo presents new opportunities to drive operational excellence and support the delivery of innovative engineering solutions. Working in a dynamic environment, you will respond to evolving technologies, production challenges, and customer requirements while contributing to the optimisation of manufacturing processes and systems. You will play a key role in the industrialisation of new products, process development and improvement, implementation of innovative manufacturing tools and techniques, and the delivery of engineering support across a diverse range of programmes. The role also offers the opportunity to contribute to sustainability initiatives, advanced manufacturing technologies, and continuous improvement activities that enhance quality, efficiency, and productivity across the business.

Responsibilities

• To be/ become the Subject Matter Expert (SME) for gear profile generation (hobbing, shaping, and profile grinding) and finish grinding (journals & cones/ thrust faces), liaising between the Design Engineering team and the machine tool operators.
• Provide technical leadership and hands‑on problem‑solving support to manufacturing and assembly teams, ensuring products are built to the required quality standards and delivered in accordance with programme schedules.
• Act as the primary interface between Engineering and Manufacturing, ensuring technical requirements, design intent, and production challenges are communicated effectively and resolved in a timely manner.
• Develop and maintain Subject Matter Expert (SME) knowledge in gear manufacturing processes, including hobbing, shaping, profile grinding, and finish grinding of journals, cones, and thrust faces, providing technical guidance to both Design Engineering and machine shop personnel.
• Assess component manufacturability and manufacturing process capability to support a right‑first‑time approach, while actively contributing manufacturing expertise during design reviews and product development activities.
• Lead Process Failure Mode and Effects Analysis (PFMEA) activities, including process mapping, risk assessment, mitigation planning, and the development and approval of manufacturing procedures and control protocols.
• Interpret engineering drawings and specifications, producing and approving manufacturing drawings and supporting documentation to facilitate efficient production.
• Ensure manufacturing plans, processes, and documentation fully incorporate Quality Assurance requirements and support compliance with internal and customer standards.
• Drive continuous improvement initiatives focused on enhancing product quality, reducing cycle times, improving productivity, and increasing process capability.
• Develop bespoke manufacturing methods, tooling, fixtures, and process solutions, ensuring compliance with Machinery Safety Regulations and safe working practices.
• Work collaboratively with cross‑functional teams including Manufacturing, Design Engineering, Quality, Supply Chain, and external stakeholders such as suppliers and auditors to achieve programme objectives.
• Create and maintain work orders, technical packs, routings, operation sheets, and manufacturing instructions to support effective production planning and execution.
• Apply a strong understanding of heat treatment processes and their impact on material properties, dimensional stability, manufacturing methods, and final product performance.

Qualifications

• Degree qualified in a relevant STEM discipline (e.g.,Mechanical Engineering, Marine Engineering), or equivalent experience.
• Professional member of a relevant engineering institution (e.g., IMechE, IMarEST, IMechE, IET).

Essential skills

• Deep understanding of manufacturing processes associated with rotating components, including turning, boring, milling, and other precision machining operations.
• Good knowledge of engineering principles, manufacturing techniques, and business systems used to support production and operational activities.
• Strong understanding of dimensional inspection methods, measurement systems, and metrology principles to ensure product conformity and quality.
• Ability to interpret complex engineering drawings and specifications, and generate or approve manufacturing‑stage drawings and associated documentation.
• Comprehensive knowledge of Geometric Dimensioning and Tolerancing (GD&T) and its application in manufacturing and inspection processes.
• Comprehensive knowledge of SAP and its application within a manufacturing engineering environment, including production routings, work orders, Bills of Materials (BOMs), and engineering change control.
• Proficient in the use of 2D and 3D CAD software to develop manufacturing layouts, tooling concepts, technical documentation, and engineering records.
• Chartered member of a relevant engineering institution (e.g., IMechE, IMarEST, IMechE, IET)

Experience

• Experience within a heavily regulated industry e.g. Marine, Aerospace, Defence etc.
• Experience in CNC programming, machining practices, and process optimisation to support efficient and repeatable manufacturing operations.

Benefits

• Collaborative working environment – we stand shoulder to shoulder with our clients and ourpeers through good times and challenges
• We empower all passionate technology loving professionals by allowing them to expand their skills and take part in inspiring projects
• ExpleoAcademy - enables you to acquire and develop the right skills by delivering a suite of accredited training courses
• Competitive company benefits
• Always working as one team, our people are not afraid to think big and challenge the status quo

• As a Disability Confident Committed Employer we have committed to:
  • Ensure our recruitment process is inclusive and accessible
  • Communicating and promoting vacancies
  • Offering an interview to disabled people who meet the minimum criteria for the job
  • Anticipating and providing reasonable adjustments as required
  • Supporting any existing employee who acquires a disability or long term health condition, enabling them to stay in work at least one activity that will make a difference for disabled people

We are an equal opportunities employer and welcome applications from all suitably qualified persons regardless of their race, sex, disability, religion/belief, sexual orientation or age

We treat everyone fairly and equitably across the organisation, including providing any additional support and adjustments needed for everyone to thrive