Senior Mechanical Design Engineer

Job Title: Senior Mechanical Design Engineer Location: Wexford

Reports to: Design Manager

Role 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.

Essential Requirements:

1. Bachelor's or Master's Degree in Mechanical Engineering or related field.
2. 8+ years' experience in mechanical design, with at least 5 in automation or special purpose machinery.
3. Proven track record in the design of complex, high-speed mechanisms and packaging equipment.
4. Expert-level proficiency with 3D CAD (SolidWorks preferred) and PDM systems.
5. Strong understanding of pneumatics, servo systems, cams, and mechanical drives.
6. Familiarity with GMP requirements, CE marking, and machine safety standards (ISO 12100, ISO 13849, etc.).
7. Strong mechanical intuition, attention to detail, and problem-solving ability.
8. Excellent communication skills, with the ability to influence across engineering and customer teams.
9. Willingness to travel (approx. 10%) for client collaboration.

Preferred Requirements:

1. Experience with pharmaceutical or medical device automation.
2. Knowledge of serialization, vision systems, or robotic integration (Delta/Cobots).
3. Understanding of Design Qualification (DQ), Factory Acceptance Testing (FAT), and Site Acceptance Testing (SAT) processes.
4. Familiarity with lean manufacturing principles and design-for-manufacture (DFM).
5. FEA and motion simulation experience (e.g., SolidWorks Simulation, Ansys).
6. Leadership experience on cross-functional project teams.

Performance Measured by:

1. Project milestones hit .
2. Reduced lost time from Waste, Motion, Re-Work, Over-Engineering.
3. Innovation; Implementation of Time and cost saving strategies .