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.