Professional Experience

JCB Heavy Products - Design engineer Mar '03 - today

Excavator OEM, part of JCB group, producing tracked and wheeled excavators

Key achievements:

▪ Designed variety of components ranging from interior plastic parts to large steel fabrications.

▪ Managed specific project areas for the design of new and current machines.

▪ Collaborated effectively with suppliers on design projects to improve product & reduce cost.

▪ Deputized for senior design engineer and supervised other engineers, as required.

Main responsibilities:

▪ Cab

Lead engineer responsible for all cab related development (interior / exterior) for current and new machines, including trim panels, controls, air-con, seating, noise suppression, vandal guards, etc.

▪ 'Auto' wheeled excavator - new range

Key design team member responsible for:

- Road lights: Design of front / rear fabrications (platforms, counterweight) to integrate new lights into excavator main body panels.

- Cab: Design / sourcing of new steering controls (steering column shroud / gaiter, cast pedals, floormat) and development of new tilting column with supplier.

- Styling: Improve overall excavator aesthetics together with JCB industrial designers

- Hydraulics: Design of electro-hydraulic circuit for undercarriage attachments

- Electrics: Design of main electrical harnesses and establish ECU software spec.

- Prototyping: Support prototype machine build and part procurement.

▪ Wheeled excavator - current model

- Packaging Design / re-location of various parts to incorporate larger engine / radiator.

▪ Design Engineering - various projects

- General Concept work, calculations, component selection, detailing, BOM.

- VA/VE: Prepare design concepts, source componentsand implement changes.

- Support: Provide technical help for quality / service issues, marketing queries.

- Official visits: TIM Cabs (France) and BAUMA construction machinery fair (Germany)

Methode Electronics - Design engineer Oct'99 - Aug'01

Automotive Tier 1 supplier manufacturing switches mainly for Ford, GM & Alfa Romeo

Main responsibilities:

▪ Project leader - FORD Park brake switch (US)

Design / project manage a product family of 5 electro-mechanical park brake switches to fulfill packaging requirements for over 20 different FORD (US) vehicle platforms (4 million/yr).

The switch went into production successfully, on time and within budget. It involved:-

- Concept design: Feasibility, CAD, FMEA, rapid prototypes, customer presentations

- Development: Coordinated multi-disciplinary project team (mould design, automation design, production & quality) to sort out technical issues and ensure project milestones were achieved.

- Design detailing: Detailed design and documentation to QS standards.

▪ Current Engineering - OPEL Ignition starter switches / Door light switches

- Involved in tackling quality / production issues on existing and newly launched switches.

- Assisted the implementation of product / process improvements for cost and quality.

▪ General Design:

- Plastic and Stamped metal part design.

- Working to tight project deadlines, including quick concept designs for competitive quotations.

Education

MSc. Engineering Design at Loughborough University Distinction 2001 - 2002

B.Eng.(Hons) Mechanical Engineering at the University of Malta 2.1 1995 - 1999

MSc. Engineering design

A practical, well-balanced course which focussed on improving effectiveness in design. It provided me with insight and useful guidelines / tools that are useful for any design role. It included:

▪ Core modules (50%): Design methods, design/ project management, CAE, structural analysis, material selection, human factors, sustainable design.

▪ Design project (50%): in collaboration with ARUP's Advanced Technology Group

"Design of a new crutch to transform a bland walking aid into an ergonomic, stylish rehabilitation product"

- Feasibility study: Market assessment, benchmarking, user requirements & design brief.

- Design: Conceptual design / development including sketches, CAD models, FEA and prototypes.

- Design feasibility: Material / manufacturing process selection, cost estimates

Languages

English / Maltese (native), Italian (excellent), German (good), Spanish (good)

Skills

Computer skills:

▪ CADNX2 Unigraphics (JCB) :- solid models, sheet metal & surfacing (UGS trained)

Pro-Engineer (Methode Electronics) :- solid modelling

Solid Edge, Autocad and Mechanica (FEA)

▪ Office tools Word, Excel, PowerPoint

Personal skills:

▪ Strong business / commercial sense, team player, creative, open-minded attitude, excellent project management and presentation skills and enthusiasm for challenging projects.

▪ Outstanding ability to understand and communicate internationally, due to previous involvement in a global student organisation (IAESTE) and regular work with foreign suppliers.