Mechanical Engineering

I completed two placements within the function covering mechanical design aspects for the internal

combustion engine, turbo and energy recovery systems. Both covered mechanical design for power

unit components through concept to manufacture and testing. Extensive use of Catia v5 for

modelling and technical drawings I also made use of knowledge gained from formal training in

geometric dimensioning and tolerancing and finite element analysis.

Performance

I developed a software tool using Matlab to analyse car telemetry data and estimate competitor

performance. As a result I gained experience of more than solely the power unit data. I also gained

experience of reviewing live event data. I later used the tool to post analyse track events, generating

technical reports based on my findings. Alongside this I developed a secondary Matlab based tool to

validate and check a specific powertrain data output.

Test Operations

I took a test from specification to results including the design of all test apparatus and conducting

the test. During this I worked within DSEAR/ATEX regulations. I worked on a project improving

facility capability, increasing an existing electrical test facility’s capability to meet specifications for

evaluating new hardware. This involved a failure investigation aspect and required me to gain an

in-depth understanding of how the facility worked and how it was required to evaluate current

hardware. Subsequently I gained a relative amount of experience in electric powertrain testing.

Reliability

I worked on developing a pass-off procedure for aspects of the energy recovery system. This

involved coordinating with multiple internal departments to manage the workload of the facility and

allow concurrent work alongside prove out of the new procedure. During this I worked with the

same facility I had previously been working on the capability improvement of during my test

operations role. Viewing the testing from both facility and product perspectives, combined with

designing hardware for the energy recovery system in my mechanical engineering roles granted me

much greater experience and understanding of the energy recovery system and electric powertrains

in general. As part of the pass-off procedure I developed several bespoke reporting tools using VBA

code granting some experience of VBA.

Quality

I completed several failure investigations during which I enjoyed a large amount of interaction with

external suppliers and gained experience with a wide range of metrology equipment and methods. I

led a project using the International Material Database System for an automotive program, requiring

collaboration with customers and suppliers and on a personal level learning the system which at the

time was covering new ground for the business.

Purchasing

I oversaw purchasing for all assembly tooling working closely with the internal department and

external suppliers to manage quality, delivery and cost. In total I looked after 21 suppliers with a

large range of parts. I completed a vendor commodity spending analysis forecasting gaps in the

supplier base for future programs. I managed the introduction of an overseas supplier for a critical

component, requiring numerous visits and the use of my experience in previous roles to ensure

internal quality standards as well as on time delivery were met.

Build Support

I designed build and assembly tooling for specialised applications. I spent a significant portion of the

time designing tooling for building, disassembling and performing checks on the energy store. This

incorporated a large focus on operator safety when working with the high voltage systems. A cost

down initiative was employed and I gained experience liaising with the suppliers of the tooling to

minimise tool cost.

Manufacturing

I designed tooling and fixtures for a range of in house manufacturing applications working to strict

cost targets. A large portion of time spent working with motor manufacture and a range of polymer

tooling, expanding my knowledge of designing for a variety of polymer manufacturing methods. I

also designed tooling for rotating machinery applications gaining experience with balancing

components and ISO 1940.