Senior NPI Manufacturing Engineer

• Jan 2022 - Present

NPI Manufacturing Engineer

• Oct 2020 - Apr 2022

New Product Introduction Manufacturing Engineer working at Brompton Bicycle

Manufacturing Engineer, Ultimate Series

• Feb 2020 - Oct 2020

Manufacturing Engineer working on the latest Ultimate Series vehicle at McLaren Automotive. Created process documentation prior to prototype builds using CAD data in Catia V5. Set up and maintained processes in the SAP ERP system including component allocation, variant coding and work instruction creation. Manufacturing sign off for engineering releases to confirm they were suitable for manufacture/assembly. Raised and resolved potential build issues through applying Design for Assembly (DFA) build principles. Adjusted working practices to remotely support the project due to Covid-19. Supported the project as part of a small team who continued to work during the height of the pandemic. Show less

Manufacturing Engineer

• May 2019 - Feb 2020

Manufacturing Engineer responsible for production planning of the A9500 Airport Runway Sweeper project. Worked in Denmark for a 4 month period as part of the product transfer to the UK where I developed a production process, identified Design for Assembly (DFA) improvements and specified tooling requirements. Developed a system using Visual Basic for Applications (VBA) to create processes, analyse process steps through an integrated Process Failure Mode Effect Analysis (PFMEA), auto populate work instruction templates and line balance the product build. The system then included the ability to display real time computer based work instructions to line operators to ensure changes were communicated as soon as possible and out of date information was no longer provided. Show less

Engineer

• Jan 2019 - May 2019

Engineer within the Market Sectors department of Ricardo helping to develop new and existing business opportunities.

Graduate Engineer

• Aug 2016 - Dec 2018

Graduate engineer at Ricardo Shoreham Technical Centre. Rotations within the Technology Strategy, Mechanical Development, Test Opterations, Engine Performance Development, New Product Introduction and Market Sectors departments.Mechanical Development:- Design Failure Mode Effect Analysis (DFMEA) support on a major client project- Engineer for engine valvetrain dyno testing using laser position sensors to measure valve lift vs cam angle. Plotted and analysed results for the client.Test Operations:- Responsible for up to 4 engine test dynos at any one time, consisting of a mix of durability and performance/emissions testing.- Skilled use of Microsoft Excel to analyse data sets checking for test accuracy, sensor drift and component failure.- Worked with a number of internal departments such as instrumentation, fabrication and calibration to maintain testing time.Engine Performance Development (EPD):- Use of Uniplot software to analyse large volumes of test bed data from CAS (Combustion Analysis).- Liaised with test engineering in the running of a performance and emissions dyno test to benchmark a production engine.- Use of Ricardo nCal to optimise engine calibration for specific emission targets.New Product Introduction (NPI):- Point of contact for Design for Assembly (DFA) issues on a major client engine project. Worked with system engineers, designers and production staff to resolve issues during prototype builds.- Process engineer introducing a new engine variant to an existing production line. Completed new work instructions and provided line support, training operators on the product and tooling.- Work of Process Failure Mode Effect Analysis (PFMEA) for new engine projects. Show less

Application Support Engineer

• Aug 2014 - Aug 2015

Placement year within the Current Product Support department at Cummins Daventry. Worked as part of the Application Support group where I was the engineering lead on a variety of customer tailoring projects on high horsepower diesel engines. Projects ranged from major changes requiring extensive validation (e.g. a remote lubrication filter system) to alternator belt tensioning options for packaging purposes. Completed a Cummins sponsored final year project for a belt driven air compressor to resolve a plant assembly issue. Achieved a final grade of 82% overall. Active in STEM activities such as the 'Big Bang' initiative and the Imagineering scheme to encourage young people into a career with engineering. Represented Cummins at local schools, the 'Big Bang' event and the 'Houses of Parliament' in London. Show less

Goodwood Revival Mechanic

• Sep 2013 - Sep 2013

Mechanic for Richard Frankel at the 2013 Goodwood Revival working on a 1963 Lister Jaguar Coupe, 1955 Ferrari 750 Monza and a 1958 Alfa Romeo Giulietta, with drivers Anthony Reid, Chris Harris, Richard Frankel and Andrew Frankel. Mechanic for Richard Frankel at the 2013 Goodwood Revival working on a 1963 Lister Jaguar Coupe, 1955 Ferrari 750 Monza and a 1958 Alfa Romeo Giulietta, with drivers Anthony Reid, Chris Harris, Richard Frankel and Andrew Frankel.

Rolling Road Assistant

• Jun 2013 - Sep 2013

Rolling Road Assistant with BRDC member Peter Baldwin working on a variety of classic road and race cars, as well as work with his Mini7 Miglia race car at circuits such as Rockingham, Brands Hatch, Snetterton, Silverstone and Zolder. Rolling Road Assistant with BRDC member Peter Baldwin working on a variety of classic road and race cars, as well as work with his Mini7 Miglia race car at circuits such as Rockingham, Brands Hatch, Snetterton, Silverstone and Zolder.