The posting
IONATE is a deep tech scale-up building the hardware and software backbone for smart grids. Our mission is to transform power systems - from grids and microgrids to renewables and data centres - unlocking the massive potential in this under-innovated sector that touches every aspect of our modern lives.
We are now looking for a Senior Production Test Engineer to join our Operations team. You will create the production-test capability needed as the Hybrid Intelligent Transformer (HIT) moves from engineering builds into safe, repeatable manufacture at London and external manufacturing partners. You will own the production-test strategy, test methods, equipment, software, safe operating controls, test records and the test elements of manufacturing transfer, working across Engineering, Manufacturing and Quality. This is a genuinely hands-on role. You should be happy working directly with high-power hardware, instruments, test rigs, software and technicians in the manufacturing and test area, solving problems at the equipment level. You will develop and implement production-test changes through the approved engineering change process.
What you will do:
- Create the production-test strategy. Own the production-test strategy by translating approved product requirements, design-verification evidence and known failure modes into test coverage, methods, sequences and proposed production limits, together with the records and release evidence required for each unit.
- Work directly on early units. Work closely with the Engineering team on production test set up and execute tests, support initial power-up and integration, capture abnormal behaviour, diagnose failures and feed practical learning back into product design, manufacturing processes and test coverage.
- Design and commission test systems. Specify, develop, integrate and validate test fixtures, harnesses, instrumentation, data-acquisition hardware, interlocks, software interfaces and operator controls that are safe, repeatable, maintainable and appropriate for production use.
- Engineer safe test operations. Define safe test methods for high-energy and high-voltage equipment, including access control, isolation, grounding, lockout and tagout, interlocks, emergency response, pre-test checks and clear operator competence requirements.
- Automate test execution and data capture. Develop or configure test software, scripts and interfaces that guide operators, reduce manual error, record results against the correct serialised unit and produce clear pass, fail and diagnostic evidence.
- Support fault diagnosis and corrective action. Use schematics, waveforms, logs, measurements and structured problem solving to isolate test failures and distinguish product defects from test-system faults. Work with Engineering, Manufacturing and Quality on containment and corrective action.
- Control test configuration and effectivity. Maintain approved test methods, software versions, fixtures, limits and calibration status. Implement test changes through the controlled change process and apply each change at a defined product serial number, lot, date or build stage with an auditable as-tested record.
- Optimise test performance and capacity. Measure test cycle time, first-pass yield, repeat tests, false failures, equipment utilisation and downtime. Improve test coverage, diagnostic value, reliability and throughput as demand grows.
- Transfer the test capability. Own the transfer of production-test specifications, equipment requirements, validation evidence, maintenance and calibration instructions, training and acceptance criteria to the UK contract manufacturer, with a scalable package for a future high-volume contract manufacturer.
- Contribute to PFMEA. Participate in developing and maintaining process FMEAs, ensuring that identified process risks, failure modes and required controls are translated into appropriate in-process and end-of-line production-test coverage, methods and acceptance criteria
Requirements
What you will need:
- A genuine preference for hands-on test work. You enjoy working directly with products, instruments, fixtures, test software and technicians. You are comfortable setting up equipment, taking measurements, modifying test rigs and troubleshooting faults in the test area.
- Relevant production-test experience. Practical experience developing, commissioning or supporting production tests for complex electromechanical, electrical, power-electronic or similarly demanding hardware.
- Electrical fault-finding capability. The ability to interpret electrical schematics, specifications, interface definitions, waveforms and logs, then use structured measurements to isolate faults safely and efficiently.
- Test-system engineering. Experience selecting and integrating instruments, sensors, switching, data acquisition, fixtures, harnesses, interlocks and operator interfaces into reliable production-test equipment.
- Test software and data. Experience developing automated test sequences, scripts or applications, with robust result capture, serial-number traceability, version control and clear diagnostic output.
- Software & Tools: Proficiency with automated test software (like LabVIEW), measurement instrumentation (multimeters, oscilloscopes), and manufacturing systems (ERP/MES like SAP).
- Safety discipline. Practical knowledge of electrical safety, risk assessment, isolation, grounding, lockout and tagout, interlocks and safe systems of work for energised or high-energy test environments.
- Controlled documentation and change. The ability to create clear test specifications, procedures, validation reports, maintenance instructions and training materials, and to manage test configuration, software versions, calibration and effectivity.
- Relevant technical foundation. A degree, apprenticeship or equivalent practical experience in electrical, electronic, power electronics, control, mechatronic, test or systems engineering, together with clear communication skills and the flexibility to support UK suppliers and manufacturing partners when required.
It would be useful to have:
- High-power product experience. Production-test experience involving power electronics, high-voltage equipment, transformers, grid equipment, energy infrastructure or another high-energy product environment.
- New-product and low-volume test. Experience creating a production-test process while product design, firmware, test coverage and manufacturing methods are still maturing.
- Automation and software tools. Experience with platforms such as LabVIEW, Python, C#, PLCs, automated test frameworks, databases, APIs, hardware-in-the-loop systems or comparable test technologies.
- Factory acceptance testing. Experience developing or executing factory acceptance tests, customer-witnessed tests, formal release evidence or site acceptance support for complex equipment.
- CEM test transfer. Experience duplicating, validating and supporting test equipment and methods at a contract manufacturer, including training, calibration, spares, maintenance and remote fault support.
Benefits
- Employee Option Plan: You get equity in IONATE, so as we succeed so do you.
- Private Medical & Dental Insurance: From day one, we provide you with full, comprehensive private medical and dental cover through Bupa. You also have the option to add any dependents to your cover. Please ask us for more details.
- Company pension: a flexible, and sustainable pension product to help you plan for your future.
- Career Development: It’s important to us that you have the opportunity for ongoing professional development and career growth. You will receive an annual budget for professional development and work with your team to set and reach goals every year.
- Flexible working schedules: You will have the flexibility for occasional work-from-home arrangements. Talk to us at the application stage about this.
- Cycle to Work Scheme: Low carbon travel is important for everyone, so we have in place a cycle scheme to help you purchase a bicycle.
- Slow travel: We believe in a low carbon future, so if you wish to travel by a lower carbon method – but it takes much longer than flying - we will give you an extra 2 slow travel days per year.
