Experience PortfolioNick Mennell, 22/04/2016

Product DesignChronological review of projects that have been designed, led, project managed and/or implemented

Land-Rover, 2¼L 4 cylinder IDi engine design (1987)

• Part of design team.

• Turbocharge existing IDI engine

• Interim solution to increase power prior to introduction of DI variant

• Low cost, fuel-efficient upgrade

• ComputerVision 2½D CAD system migrated to 3D wireframe.

• FE study on cylinder block/head

Land-Rover, 2½L 4 cylinder TDi engine design (1989)

• Led design team.

• Last production engine designed & manufactured in UK by Land-Rover

• First engine to incorporate “styled” components as it was sold to external customers including London Taxi company (black cabs)

• Included high performance plastic components

• Low cost, fuel-efficient

• Introduced CV’s 3D solid CAD system

Land-Rover Discovery – integrated 2½L TDi engine

• Project managed the new engine into the chassis, electrical & body programmes.

• Worked with styling team on first clay samples & prototypes

• Extremely tight timescale – 3 years from concept to series production.

Land-Rover, V8 engine design (1989)

• Converted existing 3.5L V8 petrol to 4.2L V8 for Australian army contract

• Manufactured in nearby engine plant

• Conceptual design for V8 diesel variant (never reached production)

Automated life-raft design (Dunlop Beaufort)

• Consultancy project

• Automated the design of inflatable life-rafts using state-of-art surface flattening (3D CAD)

• Integrated the design system with fabric cutting-system (Gerber) resulting in improved material utilisation.

• Reduced the design lead-time by over 90%

Dunlop Aircraft Tyres – tyre design

• Automated the design process to reduce the lead-time

• Improved quality of design & manufacture

Racing brake system design

• Introduced state-of-the-art CAE systems and procedures into design and development process.

• Ultra light-weight, high stiffness design. AlBeMet, MMCs, FFKM elastomers

• Capable of withstanding very high temperatures & duty-cycle. 3D C-C materials.

• Structural, thermal & fluid design

Racing clutch system design

• Diaphragm spring calculation, design & manufacture.

• 19000 Rpm

• 4½” (115mm) diameter

• 1000 Nm torque capacity

• Fully worn at 0.004”

Road-Car braking system design

• Major vehicle marques including Aston Martin, Bugatti, Caterham, Ferrari, Ford, HSV, Lotus, Koenigsegg, Morgan, Seat, and TVR

• Aesthetically pleasing

• Commercially sensitive marketplaces

• Relatively high volumes

Road-Car clutch system design

• Jaguar XJ220

Specialist brake system design (world land-speed record)

• “The Fastest Diesel in the World”A triumph for British engineering excellence and teamwork.” That was JCB Chairman Lord Bamford’s conclusion after JCB Dieselmax achieved a stunning 350.092mph (563.418kph) land speed record for diesel-powered cars.The record attempt was initiated by Lord Bamford to showcase the extreme performance capability of the JCB engine which normally powers off-highway equipment for construction, agricultural, industrial and power generation applications.The record-breaking JCB444-LSR engine displaces 5-litres, weighs 382kg (dry), and produces 750bhp at 3,800rpm and in excess of 1,500Nm of torque at 2,500 rpm. Two engines were used to set the new record at Bonneville Salt Flats USA in August 2006, with a total power output of 1,500bhp. Yet despite having twice the power and more than four times the weight of an F1 car, DIESELMAX had only half the fuel consumption.

• AP Racing purpose designed braking system.

Specialist brake system design (world’s first production plug-in EV)

• Manufactured in France for Paris street market

• Corner assemblies to include uprights, discs, calipers & drum brakes

• Actuation

• Handbrake

Racing brake corner design (Formula Renault)

• Lead the design, development & manufacturing teams to provide the “corners” for worldwide Formula Renault.

• 3 year contract

• Package included:• Upright (common front/rear)• 6 piston front caliper• 4 piston rear caliper• Master cylinders.• Balance bar

Mis-fueling system (Concept → Production)

• Lead the design, development & manufacturing teams to create the world’s first production mis-fueler (ensures correct fuel type is used)

• Public presentation including radio, TV & podcasts…

Zip G4 HydroTap®

• Introduced modern design processes to iconic Australian manufacturer.

• Collaborated on the new G4 design of HydroTap®

• Implemented ePDM, product data management system, high performance rendering, plastics design.

Smart devices - ZipAssist™

• HydroTap® communicates with the ZipAssist™ cloud server, utilises an industry standard SSL/TSL protocol and AES encryption to ensure a secure connection (unique ID).

• Advantages• Asset management• Preventative Maintenance• Alerts & Notifications• Reporting• Shared Access

Street furniture

• Designed and developed an automated image generation system from CAD system configurator for CRM system integration.

• Designed and developed a BOM generation system from CAD system to integrate with cloud-based ERP system (NetSuite).

Engineering/Manufacturing SystemsThe following details engineering/manufacturing systems that have been either implemented, used, configured, project managed or automated.

CAD (Product Design)

• ComputerVision • CADDS3 2D

• CADDS4X 3D wireframe

• CADDS5 3D

• CATIA

• CadKey

• Anvil 1000/5000

• ProEngineer

• SolidWorks

• Onshape (Cloud based)

CAE (Product Analysis)

• FEA• Systrid

• CosmosWorks

• ANSYS

• MSC Nastran

• ADAMS (Dynamics)

• Shape Optimisation• Altair Optistruct

• Fatigue• nCode

CAM (Product Manufacturing)

• Delcam (5-axis)

• CAMWorks

• MasterCAM (5-axis)

• SolidCAM

• Radan

• Esprit

ERP (Enterprise Resource Planning)

• MFG/Pro (Implemented)

• MS Dynamics AX (Implemented)

• BPCS

• NetSuite (Cloud)

• Pronto (Implemented/Upgraded)

PDM/PLM (Product Data/Life-cycle Management)

• ePDM (SolidWorks)

• Wildfire (ProEngineer)

• Enovia SmarTeam

RP (Rapid prototyping or “Additive manufacturing”)

• Software• Magics

• Hardware• Objet (MJM)

• Arcam (direct metal)

• 3D Systems (SLA)

CRM SystemsThe following details customer relationship management systems that have been either implemented, used, configured, project managed or automated.

CRM (Customer Relationship Management)

• Salesforce.com (Cloud)

• MS Dynamics AX

• Clarity

Business Information SystemsThe following details business information systems that have been either implemented, used, configured, project managed or automated.

BI (Business Information)

• Phocas (Cloud)

• MS Dynamics AX

• Salesforce (Cloud)