Senior Mechanical Design Engineer
- Wexford
- Permanent
- Full-time
Location Wexford
Reports to Design Manager
Manager of Senior Mechanical Design Engineers, Contracted Design Engineers & in house Mechanical Design EngineersRole Summary:
As Senior Mechanical Design Engineer, you will lead the mechanical design of cutting-edge secondary packaging equipment - including cartoners, case packers, tray loaders, and custom machines. You will drive design innovation, mentor junior engineers, and play a critical role in delivering high-quality solutions from concept through FAT and SAT.
Senior Mechanical Design Duties:
- Own the mechanical design of bespoke automation and secondary packaging systems
- Produce detailed 3D models, 2D manufacturing drawings, and BOMs using SolidWorks (or similar CAD software)
- Own projects from concept through to completion, including DQ, FAT, and SAT support
- Ensure designs comply with GMP, CE, and industry-specific safety standards
- Work cross-functionally with Controls, Electrical, and Project Management teams
- Perform risk assessments, DFMEA, tolerance stack-ups, and design reviews
- Collaborate with suppliers and manufacturing to optimise for cost, performance, and ease of assembly
- Mentor and coach junior mechanical designers and engineers
- Continuously evaluate new technologies, materials, and design methodologies to improve machine performance and reliability
- Plan the work using the approved Project Methodology and Standard Work-Flows and to the User Requirement Specification, through Design.
- Own Design Reviews both internally and externally.
- Check/Monitor detailed design drawings & bills of material completion.
- Maintain live and accurate data in our PDM System.
- Specification & sourcing of off-the-shelf components.
- Liaising with manufacturers and OEM equipment providers.
- Lead Design Reviews with the Automation and Electrical team so that the Machine Design foresees all of the requirements, including Mechanical, Automation, Electrical, Safety and Functional Performance.
- Champion the Company Values in relation to GMP Design, Ease of Use and Maintenance, Repeatability, Efficiency.
- Maintain the 'Sources of Truth of The Project in an Internal Design Specifications Folder so that Machine Building Team have an accurate source of reference and that Internal Pre-FAT and FAT Documents can be created.
- Generate inputs required for Machine Manuals and other client required Documentation.
- 8+ years' experience in mechanical design, with at least 5 in automation or special purpose machinery
- Proven track record in the design of complex, high-speed mechanisms and packaging equipment
- Expert-level proficiency with 3D CAD (SolidWorks preferred) and PDM systems
- Strong understanding of pneumatics, servo systems, cams, and mechanical drives
- Familiarity with GMP requirements, CE marking, and machine safety standards (ISO 12100, ISO 13849, etc.)
- Strong mechanical intuition, attention to detail, and problem-solving ability
- Excellent communication skills, with the ability to influence across engineering and customer teams.
- Willingness to travel (approx. 10%) for client collaboration.
- Knowledge of serialization, vision systems, or robotic integration (Delta/Cobots)
- Understanding of Design Qualification (DQ), Factory Acceptance Testing (FAT), and Site Acceptance Testing (SAT) processes
- Familiarity with lean manufacturing principles and design-for-manufacture (DFM)
- FEA and motion simulation experience (e.g., SolidWorks Simulation, Ansys)
- Leadership experience on cross-functional project teams
- Reduced lost time from Waste, Motion, Re-Work, Over-Engineering
- Innovation; Implementation of Time and cost saving strategies