Senior NPI Engineer

Ensera Design; Bristol; On-site; GBP 62,000 - 74,000; Full time

Job summary

A leading product development consultancy in Bristol seeks a Senior NPI Engineer to lead process optimisation for new medical devices. The role requires collaboration with various teams, development of assembly processes, and ensuring compliance with health and safety regulations. Ideal candidates should have experience in medical device manufacture, strong analytical skills, and proficiency in CAD. The position offers a competitive salary up to £73,954, along with flexible working, private healthcare, and additional benefits.

Benefits

Performance-related company-wide bonus

Flexible hybrid working

Private healthcare

Enhanced maternity and paternity leave

Salary exchange pension scheme

25 days annual leave

Training and development opportunities

Qualifications

• Experience in medical device manufacture.
• Strong analytical and problem-solving skills.
• Excellent communication and interpersonal abilities.

Responsibilities

• Lead process optimisation and design for assembly.
• Interface between design and manufacturing teams.
• Setup small batch assembly of prototypes for clinical trials.

Skills

Assembly process design

Process development

Client relationship management

Risk management process to ISO14971

Proficiency in process simulation software

Education

Relevant degree in engineering or related field

Tools

CAD (preferably SolidWorks)

Job description

Ensera Design is a world‑class user‑centred innovation and product development consultancy, specialising in the medical and consumer health sectors. As part of the Ensera Group, we collaborate globally with contract manufacturing facilities in Europe, the USA, and Asia, alongside additional design and product development teams in New Jersey and Colorado.

We are currently seeking an experienced Senior NPI Engineer to join our talented team and contribute to delivering exceptional solutions for our clients.

About you

You are a Senior NPI Engineer working in consultancy or industry or at a start‑up within the medical device sector.

• You are a driven, self‑starter, ready to lead the process optimisation and design for assembly thinking, as part of our medical device development team working on a new medical device.

• You will form the interface between our design and development and manufacturing teams.

• You will lead the setup of small batch assembly of prototypes for clinical trials.

• You are comfortable working at the front end on new product development projects where there is a high degree of uncertainty.

You will bring your own skills to add depth to our team, so you’ll need to be a team player who thrives on collaborating with mechanical engineers, designers and manufacturing experts.

Your skills and experience

Whilst you do not need to meet all of these points, please ensure you meet the majority of them before making an application:

• A keen focus on assembly process design and process development

• Experience of the design and implementation of new processes and technologies as part of product development, providing feedback on product design.

• Experience of analysing and evaluating existing processes to identify inefficiencies and areas for improvement.

• Experience of developing and implementing process optimisation strategies to enhance productivity and reduce costs.

• Experience of ensuring compliance with health, safety, and environmental regulations.

• Maintain documentation of process changes and updates.

• Experience of developing processes including bonding, ultrasonic welding, manual assembly and automated or semi‑automated assembly.

• Experience in the design and introduction of production lines including fixture design

• Capable of reviewing and working in CAD, preferably SolidWorks

• Experience in medical device manufacture

• Experience in risk management process to ISO14971 and use of PFMEA

• Excellent presentation skills including written and verbal communication skills

• Excellent client relationship management (ideally consultancy experience)

• Strong analytical and problem‑solving skills.

• Excellent communication and interpersonal abilities.

• Proficiency in process simulation and modelling software.

• Knowledge of lean manufacturing principles and continuous improvement methodologies.

Please note our salary band for the Senior level goes up to £73,954. We ask you to indicate your desired salary as part of your application.

Why work with us?

Ensera Design offers interesting and varied work combined and a supportive team culture to provide a stimulating environment where you will have the opportunity to develop and learn from others. We offer flexible working policies where working patterns are agreed with our line managers, taking into account the role, needs of the individual and the team.

We recognise that we are only as good as our people and we know how important it is to support our team.

We offer:

• Performance‑related company‑wide bonus.

• Flexible hybrid working in line with our core hours (Mon–Thu, 9:30am–12:00pm & 2:00pm–4:00pm; Fri, 9:30am–12:00pm).

• Private healthcare for you and your family.

• Enhanced maternity and paternity leave.

• Salary exchange pension scheme.

• 25 days of annual leave, plus the option to purchase up to one working week and additional days for length of service.

• Access to our Employee Assistance Programme and digital wellbeing platform.

• Cycle to Work & Electric Vehicle Lease schemes.

• Death in service (x4 gross salary).

• Training and development opportunities, including dedicated learning days and regular knowledge‑sharing sessions.

• A free lunch the first Monday of every month alongside our company‑wide meeting.

• Free breakfast every Wednesday, and plenty of opportunities to socialise, including team‑organised activities, summer and Christmas parties, and more.

About us

Ensera Design is based in an iconic Grade II listed building in the heart of Bristol. Our vibrant workspace houses state‑of‑the‑art labs, a design studio, usability suites, and collaborative meeting spaces. Nestled in a lively neighbourhood with independent shops, we’re just a short walk from Park Street, the Harbourside, and St. Nick’s Markets.

Our values

We are proud of our values:

• Find a way: We work as one team, combining our knowledge and experience to unite around a shared goal. We trust each other and do what’s needed to get things done and exceed expectations.

• Pull together: We believe anything is possible. When faced with challenges we take the initiative, using our creative spirit and determination to find bold solutions and deliver results that move us forward.

• Care: We act with integrity, take pride in our work, and support each other. We each play our part to make a positive impact for our customers, our colleagues, and our planet.

Our diverse, multidisciplinary team spans research, design, human factors, engineering, prototyping, manufacturing, and beyond. Together, we deliver cutting‑edge solutions for clients ranging from global leaders to innovative start‑ups, with a particular focus on medical devices, drug delivery, orthopaedics, and diagnostics.

Do we sound like a good match for you?

If you’d like to discuss the role or would like to discuss any reasonable adjustments you may need to make your application, we’d love to hear from you. If you think you might be the right person for us but want an informal chat first then get in touch via

[e-mail].

Please note we reserve the right to close the vacancy if we have a high level of applications. We look forward to hearing from you!

At Ensera Design we believe that designing for people means including all people, starting with the team behind the work. Our human‑centred design ethos is rooted in empathy, and our values – pull together, find a way, and care – guide us in building a team that reflects the diversity of the world we design for.

We know that different perspectives lead to better ideas, stronger collaboration, and more meaningful outcomes. If you meet the skills and experience for this role, we welcome your application – whatever your background, identity, or path into design. What matters to us is that you share our belief in purposeful, people‑first design.