Senior Mechanical Design Engineer

Greg O'Hanlon International Ltd; Leinster; On-site; EUR 70,000 - 80,000; Full time

Job summary

Greg O'Hanlon International Ltd is seeking a Senior Mechanical Design Engineer to lead the mechanical design of cutting-edge secondary packaging equipment in a full-time, site-based role in Co. Wexford, Ireland.

The role focuses on cartoners, case packers, tray loaders and custom automation systems, offering clear career progression. You will report to the Design Manager and collaborate with Electrical, Controls and Project Management teams while engaging with clients and suppliers to ensure

Qualifications

• Bachelor’s or Master’s Degree in Mechanical Engineering or related field.
• Minimum 8 years’ experience in mechanical design, 5+ in automation.
• Experience with GMP/CE standards and risk assessments.

Responsibilities

• Lead the mechanical design of bespoke packaging and automation systems, ensuring high-speed functionality and compliance with GMP and CE.
• Develop 3D models, 2D drawings, and BOMs using SolidWorks and PDM.
• Manage design projects from kick-off to DQ, FAT, SAT and handover.
• Conduct tolerance stack-ups, DFMEA, motion studies and design risk assessments.
• Plan and run design reviews aligned with URS and documentation standards.
• Collaborate with automation, electrical and controls teams for integrated systems.
• Source off-the-shelf components; liaise with suppliers and manufacturing for cost-effective solutions.
• Maintain live data in PDM and manage the Design Specifications folder.
• Support machine manuals, customer docs and technical handover materials.
• Mentor junior engineers and lead client meetings through the project timeline.
• Champion values around ease of use, repeatability, safety and serviceability.
• Drive continuous improvement and cost-reduction initiatives.

Skills

8+ years mechanical design

High-speed packaging

Lead automation design

Detail-oriented engineering

Education

Bachelor’s or Master’s Degree in Mechanical Engineering

Tools

SolidWorks

PDM systems

Ansys / SolidWorks Simulation

Job description

Based in the “sunny South East” our client is a rapidly expanding company focused on shaping the future of robotic automation. The company designs, manufactures, and integrates custom robotic automation solutions for various industries including Pharma, Food and Life Science. They serve an international customer base, enabling increased efficiency and competitiveness for their clients.

We are seeking a Senior Mechanical Design Engineer to lead the mechanical design of cutting‑edge secondary packaging equipment, including cartoners, case packers, tray loaders, and custom‑built automation systems. This is a key role within the engineering team, responsible for driving innovation, mentoring junior staff, and delivering robust technical solutions from concept through FAT/SAT and customer sign‑off.

You will report directly to the Design Manager, working closely with Electrical, Controls, and Project Management teams, while engaging with clients and suppliers to ensure design excellence and manufacturing efficiency. This is a full‑time, site‑based role in Co. Wexford, Ireland, offering significant career progression opportunities within a growing and forward‑thinking business.

Responsibilities

• Lead the mechanical design of bespoke packaging and automation systems, ensuring high‑speed functionality, robustness, and compliance with GMP and CE standards.


• Develop detailed 3D models, 2D manufacturing drawings, and bills of materials (BOMs) using SolidWorks and associated PDM systems.


• Manage design projects through the full lifecycle -from kick‑off and concept to DQ, FAT, SAT, and handover.


• Conduct tolerance stack‑ups, DFMEA, motion studies, and design risk assessments in support of system integrity and reliability.


• Plan and execute internal and customer‑facing design reviews, ensuring clear documentation and technical alignment with the User Requirement Specification (URS).


• Collaborate with automation, electrical, and controls teams to deliver fully integrated systems.


• Specify and source off‑the‑shelf components; liaise with suppliers, OEM partners, and manufacturing to ensure cost‑effective and practical solutions.


• Maintain live, accurate data in the PDM system and manage the internal Design Specifications folder for reference and documentation.


• Support the generation of machine manuals, customer documentation, and technical handover materials.


• Mentor and guide junior engineers, supporting skills development and PDM usage.


• Lead and participate in client meetings throughout the project timeline.


• Champion company values around ease of use, repeatability, serviceability, and safety.


• Support continuous improvement, cost reduction, and design efficiency initiatives.

Candidate Requirements

• Bachelor’s or Master’s Degree in Mechanical Engineering or a related field.


• Minimum 8 years’ experience in mechanical design, with at least 5 in automation or special purpose machinery.


• Proven expertise in the design of high‑speed mechanisms, packaging equipment, and complex assemblies.


• Advanced proficiency in 3D CAD tools (SolidWorks preferred) and PDM systems.


• Strong knowledge of pneumatics, servo systems, cams, and mechanical drive systems.


• Experience working to CE compliance, GMP standards, and machine safety norms (e.g. ISO 12100, ISO 13849).


• Excellent mechanical intuition, engineering judgement, and attention to detail.


• Strong communication skills, capable of working across engineering teams and engaging with clients.


• Ability and willingness to travel (~10%) for client collaboration and on‑site reviews.


• Full Irish driving licence.


• Experience in pharmaceutical or medical device automation is a plus.


• Familiarity with robotic integration (e.g., Delta robots, cobots), vision systems, or serialization solutions is a plus.


• Experience with FEA or motion simulation tools (e.g. SolidWorks Simulation, Ansys) is a plus.


• Understanding of Design Qualification (DQ), FAT, SAT, and equipment validation processes is a plus.


• Exposure to lean manufacturing principles, DFM (Design for Manufacture), and value engineering is beneficial.


• Prior experience leading cross‑functional design teams or technical project groups is a plus.

Remuneration

Salary for this role is in the range of €70,000–€80,000 per year with an EBITDA bonus structure, depending on experience and fit for the position.