Research And Development Engineering Head

ROLE: We need someone who can take what R&D produces at prototype stage and turn it into a line series production system reliably, on time, and to defence-grade quality standards. Zen Technologies builds complex, multi-disciplinary defence products combat training simulators and counter-drone systems. The engineering involved spans mechanical, electrical, electronics, software integration, and system-level testing. The Head of Engineering owns the transition from the R&D bench to the production floor, and everything that sits between those two points. This is not a process-management role. It is a hands-on, technically deep, leadership position. The person must understand drawings, BOMs, quality plans, supply chain constraints, and team dynamics all at the same time. WHAT THE ROLE INVOLVES: 1. R&D to Production Translation Understand production requirements and interpret R&D-level designs emerging from prototype build-up phases. Translate R&D drawings and specifications into detailed, production-grade engineering documentation across all disciplines mechanical (part and assembly drawings, GD&T, tooling layouts), electrical (wiring harness, panel schematics, power distribution), electronics (PCB assembly, component placement, test point documentation), integration (ICDs, system assembly sequences), and testing (ATPs, functional checklists, burn-in protocols). – Identify and resolve DFM and DFA gaps between R&D intent and production realities before they reach the floor. – Maintain version-controlled engineering master records aligned with the company's change management process. – Coordinate with the R&D team during proto phase — understand design intent, flag producibility issues early. 2. MQAP and Production Tooling – Develop Manufacturing Quality Assurance Plans (MQAP) for all product lines. – Design and commission production jigs, fixtures, test rigs, and tooling for first-article and series production. – Establish inspection criteria, FAI processes, and in-process quality gates. – Familiarity with DGQA, BQS, and defence acceptance processes is required — products go through military quality audits and field trials before delivery. – Drive continuous improvement through root cause analysis, CAPA, and lessons-learned integration. 3. AI-Assisted Engineering – Identify and deploy existing AI-based engineering tools to accelerate first production-level system build-up. – Use AI/ML tools for automated drawing generation, design rule checks, BOM extraction, and clash detection where available. – Champion AI-driven BOM comparison to cross-validate Production BOM against R&D BOM — flag and resolve discrepancies, part number mismatches, and specification deviations systematically. – Promote digitised work instructions, e-travellers, and MES integration across the production floor. 4. BOM Management – Own end-to-end Production BOM generation, structuring, and maintenance in the ERP/PLM system. – Conduct structured BOM reconciliation reviews between R&D BOM and Production BOM at each product release milestone. – Minimise BOM discrepancies through disciplined ECN/ECO processes. – Ensure all BOM revisions are reflected in MRP/ERP in real time to prevent procurement and production errors. 5. Material Planning and JIT Supply Chain – Define material requirements aligned with an optimised JIT manufacturing cycle. – Manage input materials across three categories: JIT items ordered on-demand; common high-velocity items buffered against lead time variability; and long-lead, regulatory-constrained, or technologically obsolescent items managed proactively with safety stock and approved alternates. – Coordinate with procurement to issue material release schedules, track supplier delivery performance, and resolve shortages. – Manage EOL component risks; lead last-time-buy decisions in coordination with R&D and supply chain. – Defence supply chains have unique regulatory and ITAR/export control dimensions — the role requires familiarity with these constraints. 6. Quality and On-Time Delivery – Ensure all product deliveries meet agreed quality specifications — on time, in full. – Maintain engineering sign-off for all production releases. – Collaborate with QA on customer complaints and field failure analysis; implement systematic corrective actions. – Support customer acceptance trials and military user evaluations at field locations when required. 7. Team Leadership – Lead a multidisciplinary engineering team across mechanical, electrical, electronics, integration, and test functions. – Set clear performance goals, conduct structured reviews, and hold team members accountable. – Identify skill gaps and drive targeted training; build succession depth. – The expectation is a hard task master with genuine empathy — high standards, clear accountability, and real investment in people's growth. Both sides of that are non-negotiable. WHAT WE ARE LOOKING FOR: Essential: – B.E./B.Tech in Mechanical, Electrical, Electronics, or Systems Engineering. – Minimum 15 years of engineering experience, with at least 5 years in a production or manufacturing engineering leadership role. – Demonstrated experience translating R&D or prototype designs into series production across multi-disciplinary domains. – Proficiency in engineering drawing tools — SolidWorks, AutoCAD, CATIA, Altium, or equivalent. – Hands-on experience with ERP/PLM systems for BOM management (SAP, Oracle, Windchill, Teamcenter, or similar). – Working knowledge of JIT manufacturing, MRP planning, and supply chain management. – Experience managing long-lead, regulatory-constrained, and EOL/obsolescent component strategies. – Experience developing and executing MQAP, FAI processes, and quality systems (ISO 9001 or equivalent). Preferred: – Experience in defence, aerospace, or high-reliability manufacturing environments — defence sector experience is a strong advantage. – Familiarity with DGQA or military quality acceptance processes. – Understanding of ITAR, export control, or defence procurement regulations. – Exposure to AI-assisted engineering workflows — generative design, AI BOM comparison, LLM-assisted documentation. – Lean manufacturing or continuous improvement background.