Senior New Product Engineering Manager (NPI)

Frontier are looking for an NPI (New Product Introduction) Engineering Manager for a high-impact leadership role responsible for bridging the gap between R&D and full-scale manufacturing. The following specification outlines the core responsibilities, qualifications, and technical skills required for this position based on current industry standards. 

What You Will Do:

• Strategic Leadership: Direct a cross-functional team of manufacturing and process engineers to design and industrialise new electronic products, from initial design concept (RFQ) through to full production handover.


• Lifecycle Management: Lead products through formal stage-gate processes (e.g., AS9145, APQP) from initial bid and concept to production handover.


• Design for Excellence (DfX): Champion Design for Manufacturability (DfM), Testability (DfT), and Cost (DfC) to ensure designs are robust and cost-effective.


• Risk Mitigation: Manage Manufacturing Readiness Levels (MRL) and conduct Failure Mode and Effects Analysis (FMEA) to identify and resolve production risks early.


• Supply Chain Integration: Collaborate with procurement and external suppliers to ensure component availability and manufacturing capability.


• Risk Mitigation: Proactively identify and resolve technical or supply chain risks using PFMEA and root-cause analysis (RCCA).


• Technical Reporting: Establish project baselines for cost, schedule, and quality, providing regular updates to senior leadership and customers.


• Cost & Schedule Control: Establish and monitor project baselines for cost, schedule, and scope, frequently reporting progress to senior stakeholders. 


• Process Development: Drive the creation of manufacturing plans, work instructions, tooling, and fixture requirements.


• Cross-Functional Coordination: Align diverse departments—including R&D, Quality, Supply Chain, and Operations—to achieve successful launch goals.


• Manufacturing Readiness: Oversee Manufacturing Readiness Level (MRL) assessments and maturation plans to ensure production lines are capable and stable.


• Gate Review Management: Chair and manage NPI Gate processes, Design Gate reviews, and Production Readiness Reviews.

Qualifications You Must Have:

• Education: A Bachelor’s or Master’s degree in Electrical, Electronic, or Manufacturing Engineering.


• Experience: Significant experience in a manufacturing environment, with at least 2–3 years in a leadership or management capacity.


• Sector Expertise: Proven track record in a highly regulated environment, such as Aerospace (AS9100/9102), Defence, or Space.


• Standards Knowledge: Expertise in industry-specific standards such as AS9100, AS9145 (APQP/PPAP), and J-STD-001.


• Security Clearance: Ability to obtain and maintain national security vetting (e.g., UK SC or US Secret clearance) is often mandatory. 


• Project Management: Proficiency in project management tools (e.g., MS Project, Smartsheet) and methodologies (PMP or PRINCE2 certification is highly desirable).


• Security Clearance: Ability to obtain and maintain national security clearance (e.g., SC or Secret clearance) is a standard requirement for defence-related roles.


• Electronics Expertise: Deep understanding of PCBA (Printed Circuit Board Assembly), SMT (Surface Mount Technology), and microelectronics assembly processes.


• Methodologies: Proficiency in Lean Manufacturing, Six Sigma, and project management frameworks such as PRINCE2 or PMP.


• Systems Proficiency: Skilled in using ERP/MRP tools (e.g., SAP, Oracle) and PLM software for configuration control and BOM management.


• Testing & Quality: Deep understanding of PFMEA, Root Cause Analysis (RCCA), and automated test equipment (ATE) for electro-mechanical systems. 


• Analytical Ability: Strong data-driven decision-making skills to optimise cycle times and reduce unit production costs. 


• Design for Excellence (DfX): Deep understanding of Design for Manufacturability (DfM) and Design to Unit Production Cost (DTUPC).


• Technical Interpretation: Ability to interpret complex drawings, Bill of Materials (BOMs), and GD&T specifications.


• Advanced Manufacturing: Knowledge of CNC machining, automation, special processes (e.g., heat treating, welding), or electronics assembly (SMT/CCA).

Excellent salary and package on offer – relocation applications welcome.