Senior Process Engineer


Manufacturing and tooling, Energy storage, Mechanical Engineering
Malmesbury - United Kingdom


There is a requirement for a senior manufacturing engineer to lead the scaling and industrialisation of manufacturing processes for new and innovative energy storage technologies. This person will be part of a multi-disciplinary team of innovators, all experts in their respective fields, working to advance the technology and manufacturing readiness of energy storage technologies. Their role in this team will be to develop manufacturing processes from the research phase, through pilot scale manufacture and onwards to serial production.


• Work with the project team to identify and capture the product characteristics and translate these to define the parameters of the manufacturing processes and, subsequently, the associated manufacturing equipment and tooling. • Detail a plan for scale up of the manufacturing processes and equipment, from research to production. Identify the activities and milestones necessary to prove progression in the maturity of the manufacturing technology. • Compare alternative methods of manufacturing and engage with vendors of manufacturing equipment to evaluate the options for scale up of manufacturing. Construct clear and robust arguments for the down-selection of specific process and equipment technologies. • Employ process engineering tools and techniques to develop and optimise chosen technologies such that they meet product and project requirements of cost, quality and delivery. • Define clear specifications for manufacturing equipment to aid the identification suitable equipment vendors. Support the development of business cases to secure capital funding for the acquisition of such equipment. • Use process simulations and practical experiments to validate theoretical calculations of process performance and create manufacturing cost models to verify economics of the processes in each stage of production scale-up. • Design the layout of manufacturing facilities and specify the requirements and constraints placed on such facilities due to the manufacturing process and equipment. • Specify technical instructions for operation of manufacturing processes. Ensure that all risks associated with the processes have been effectively managed such that they are as low as reasonably practicable. • Complete the commissioning of manufacturing equipment and ensure that all required certifications and approvals required for the operation of the equipment are secured. • Ensure that quality is built in to the manufacturing process and specify suitable methods of measurement and inspection. Complete statistical studies to prove that gauges achieve required levels of accuracy and precision. • Verify manufacturing process capabilities and capacities at each phase in the development of the manufacturing process. Work progressively, from the research laboratory, through industrialisation, to demonstrate that manufacturing processes will achieve their targets.


• Undergraduate or post graduate degree in a scientific or engineering discipline • Significant experience working in an industrial environment with at least 5 years of experience in manufacturing or process engineering • Proven track record of scaling and industrialising manufacturing processes and equipment from laboratory research through to serial production • Applied knowledge of methodologies for new product introduction and manufacturing technology development • Familiarity with tools and techniques for process optimisation, quality engineering, design-for-manufacture and cost modelling. • Expertise in at least one of the following methods of manufacture: o Die and laser cutting of metallic foils;o Precision assembly with thin-film components; o Ultrasonic and laser welding of metallic foils; o Forming of sheet and laminate materials. o Bonding of thermoplastic materials; o Vacuum pressure wetting of microporous materials.  Desirable Qualifications and Experience  • Chartered Engineer or Chartered Scientist • Experience of processes used in the manufacture of secondary batteries • Familiarity with PLM, CAD, CAM, ERP and MES systems • Experience using virtual manufacturing and process simulation tools


27 days holiday plus eight statutory bank holidays

Pension scheme

Performance related bonus

Life assurance

Sport centre

Free on-site parking Subsidized café and restaurants

Discounts on Dyson machines

Posted: 29 May 2019