Reflective Report based on placement experience

What would you say if I told you that most designs are conceived by engineers who employ their creative minds to open their eyes and begin problem solving? Although problem solving is the most important aspect to note, the design must be appealing and fascinating enough to draw attention. Therefore, the incorporation of human touch into design validates not only the aesthetics but also the functionality of the whole system. During my internship at Lorro Precision, I took a significant stride forward in my career as a professional mechanical design engineer by implementing a plan to monitor my commercial awareness, leadership attitude, professional growth, and dedication to continuous learning.

My day to day activities

Even though I have a 9-to-5 job, I am still excited to think about how I can bring a new product to market. But building a great product is not easy and it takes extra passion, interest, and motivation. I do experiments as a mechanical design engineering intern by creating physical and visual representations of the most crucial concepts and functionalities of mechanical engineering domain. I often get engaged in developing and testing physical prototypes in the workshop. I utilise 3D CAD and CAM software to plan and execute mechanical designs while collaborating on design studies to address issues that arise during the production development phase. I often have to use computer simulations to test and improve designs before they are made. The most fun part is when I use 3D CAD to design parts that work. I can easily set up and run a 3-axis CNC machine and use a 3D printer to make the product, all while following strict maintenance and safety rules.

Fig: Magnet bracket designed on Fusion 360 and printed on Ender 3 v2

My cultural understanding of Lorro Precision according to McKinsey's 7S model

The methodology that can be used to assess the potential consequences of upcoming organisational changes or to synchronize units and procedures after a consolidation or takeover is defined below (Teybeh, A., Nejad, Mohammad, R., Behbodi and Mohammad Mehdi Ravanfar, 2015):

• Strategy: This refers to an organization's approach for creating and sustaining a competitive edge over its rivals.

• Architecture: This describes the organisation of functions and groups, including who is responsible for what.

• Systems: the routine tasks and practises used by workers to do their work.

• Common Values: These represent the fundamental principles of the company and its overall work ethos.

• Leadership style: the attitude used to pave the right way to co-workers.

• Personnel: the staff members and their overall talents.

• Competencies: The workers of the organization's genuine abilities and competencies.

Since Lorro Precisoon is a small CNC high precision manufacturing company, they primarily use 3D CAD to bring the client's product concept to life, requiring the employee's superior analytical and engineering design skills to satisfy the client's needs and maintain a competitive edge; thereby securing more contracts to meet the company's business needs. Mr. Laurence Symonds is primarily responsible for the organization's general structure and decision-making capacity. As this company offers engineering design and manufacturing services, the workforce must apply fusion 360 CAD/ CAM software to transform drawings into manufactured goods. In addition, the staff's goal is to increase the company's profit and growth rate, so gaining a stronger competitive edge to get more customer orders.

Fig: Parts fabricated by lathe machine

Skills and knowledge obtained

Subject-specific knowledge and engineering fundamentals are required to delve deeply into the field of the engineering design and manufacturing. The utmost effort a mechanical design engineer can do is to successfully integrate design ideas with 3D CAD software. In addition, an intuitive understanding of Computer-aided Manufacturing, 3D printing, and CNC machining is necessary to suit the customer's needs and solve the issue.

Gaps in knowledge

Electrical cooling and electrical design to construct a mechatronic component is the knowledge gap I discovered most often when working on a project involving a remote-controlled automobile. In addition, I have neglected to include simulation methodologies such as static and dynamic simulation in simulation-based projects. In addition, I am now practising programming skills such as Python and Matlab in order to do complex projects.

Challenges experienced in the workplace so far:

An accurate depiction of a feeling, whether pleasant or negative, is provided by Gibbs Reflective Cycle The description of the event, the sentiments evoked, and the assessment and analytical approach to reflect on any experience are the fundamental elements of this model (Adeani, I.S., Febriani, R.B. and Syafryadin, S., 2020). Additionally, the attractiveness of the Borton's framework, which was devised in the 1970s and consists of just three questions, is due to its simplicity. It begins with ‘What?’ and prompts the reflector to narrate what has occurred. It inquires about the responsibilities of those involved and what transpired when the situation occurred. After that, the question comes with 'so what?’ which leads to the study of the reflection. What Now?, which focuses on next steps and the consequences of learning experiences for future practise, is one of the most crucial parts of a reflection (Skinner, M. and Mitchell, D. , 2016).

I became acutely cognizant, while working with Lorro Precision, that I had been missing in basic engineering concepts and workshop tools to address engineering design and manufacturing domain-based tasks. For instance, I discovered that I knew very little to nothing about the various tooling, nuts, bolts, and even mechanisms usually employed in the solution of those tasks while I was working on a machine design project. I need to brush up on my fundamental engineering concepts utilising RS Khurmi's Mechanical Engineering subject specific objective book. After that, having a thorough grasp aids me in further tasks involving CNC machines and 3D printing.

Fig: Designing on CAD software for a machine design project

I found I knew very little about CNC machining and lathe machine operation while working on this machine design project. To tackle the issue, it is critical to understand the machining process in depth. This project requires the design of a motor ring roller that must be mounted with an adjacent bracket. The bracket must be manufactured using a three-axis CNC milling machine and simulated using Fusion 360 Cad/ CAM. Because this is my first professional assignment, I need to solve the problem and overcome the knowledge gap as quickly as feasible. After reviewing all of the fundamentals, I solved the issue by testing some of the existing research strategies, and my boss was overjoyed.

Reflect on these experiences and relationships with co-workers/managers

As a young engineer, I believe it is reasonable to not comprehend all of the fabrication techniques. While doing on a client project during my placement, I need to understand the tactics used in welding. As a result, I requested my manager to demonstrate the MIG welding procedures to me. I effectively formulated and delegated the project after carefully examining the processes.

Fig: Observing welding process

Management/Leadership Self-Assessment

Paul Hersey and Ken Blanchard, writer of The One Minute Manager, devised the Hersey-Blanchard Model. The model is not constant. Rather, it's adaptable, with the manager responding to workplace conditions like employee engagement. Model-following managers must adopt a leadership style based on member maturity. If followers are competent, the model proposes little direction. If follower maturity is poor, the manager may need to issue precise directives and actively oversee activities to ensure the group understands its objectives and how to attain them (Cairns, T.D., Hollenback, J., Preziosi, R.C. and Snow, W.A., 1998).

According to Myers-Briggs Type Indicator (MBTI) leadership characteristics (Mccaulley, M.H., 1990), I am a detail-oriented leader who strives to ensure that the individuals I lead have a strategic roadmap, regular, authentic supervision, and a rational course of action. Because I have an insatiable need to organise people and coordinate work, I take the time to verify that their plans are precise, correct, and fact based. I help to assure that everyone appreciates where they're headed and how to get there. When making choices for a business or team, I consider the factual details first, followed by the merits and drawbacks. I strive to be impartial and fair throughout. However, I can get so engrossed in the specifics of a situation that I lose track of the wider context. Straight forwardness and compassion are difficult for me. In the near future, I want to develop emotional intelligence.

Fig: Workshop placement

Fig: CNC machined precision components

My management and leadership attitude with an example

I need to operate and set up the 3 axis CNC machine while working on a large customer project. I can conceive of any difficulty that may develop in the near future because of my intriguing persona and professionalism. The root problem must be addressed, and it is only in this manner that the problem may well be treated entirely. As a result, I spend more time to think about the system's entire process, which forces me to contemplate the pipeline's bottom. While working on a project involving a CNC-machined precision component, I took into account the general challenges of production as well as the resource constraints. Following that, I was able to reduce processing or machining time while maintaining the high level of quality the customer required.

Professional Development Plan

Professional development planning is structured frameworks one can use to be aware of skills they have, identify and develop skills, and work out what one wants to achieve and how to achieve it. It is a structured process to develop own capacity to reflect on learning and achievements.

Aims and Objectives

·        Successfully becoming a mechanical design engineer

·        In-depth grasp of design concepts, manufacturing guidelines (Plastic, sheet metal, CNC, and 3D printing), and fundamental mechanical calculations covering structural, fluid, thermodynamics, heat transport, and machine building design.

·        Acquiring expertise with 3D CAD and CAM technologies, particularly parametric modelling and milling/turning processes

·        Understanding the various prototyping strategies and using analytical and simulation abilities to validate the design prior to production.

·          Learning a variety of simulation and modelling methods, including injection moulding, linear and nonlinear analysis, vibration, buckling, and modal frequency analysis ( Abaqus and simscale simulation software are here to learn)

·        Integrating electrical and electronic components into mechanical design elements to create a successful product if I choose to become an entrepreneur in the future (PCB design and electrical routing design abilities are essential. Here, robotics hardware and mechatronics design expertise must be mentioned)

·        Automate the design activities and incorporate programming abilities into design theory in order to save time and boost output. (eg; matlab software)

Qualities and skills to be developed

·        Subject-specific expertise and engineering basics (Heat transfer, material science, fluid dynamics, CFD, mechanics, machine design)

·        Design principles and integrating effectively into the 3D CAD world 

·        Knowledge of Computer-aided Manufacturing

·        3D printing and CNC machining

·        Electrical cooling and electronic design to create a mechatronic component.

·        Simulation methods such as static and dynamic simulation

·        Programming expertise such as Python and Matlab

Benefit received

·        After 10 years of being a successful designer, fabricator and entrepreneur, one may find well-paying employment.

·        Jobs dedicated only for exceptional abilities, intellects, and creative minds

·        Utilizing theory in practise

·        Solving difficulties for human kind

·        Contributing to the economy of my country by introducing my unique product to the market (these are plans created after 10-15 years)

Strategies to achieve objectives and evolution as a manager/leader

·        Taking a course online that pertains to mechanical design, simulation methodologies, manufacturing concepts, and electronic systems

·        Conducting many mechanical design projects from idea to fast prototype

·        Utilizing LinkedIn to network with qualified engineers and designers in order to get an entrepreneur position

·        Visiting workshops to get practical experience; comprehension of design and production regulations

·        Improving communication skills to connect with peers and superiors and going in the proper direction to become a leader in the industry after five years

·        Participating in volunteer engineering-related efforts

Timeframe for achievement

Continuous learning is a process. In the next 1 year, I intend to:

·        6 months for mastery of 3D CAD

·        Manufacturing knowledge acquisition in sheet metal and plastics design: 5 months

·        4 months for using simulation approaches to test the product

·        Utilizing programming skills to design micromechanical components and associated control systems: 7 months

Fig: Designed and printed a CNC machine tool holder by 3d Printer

Theory

Practical implications are always built on existing theory and this theory's foundation to solve engineering problems that develop around us. The design guidelines must be followed and maintained when working on a 3D printing project. Otherwise, the outcome may not be what was anticipated.

In the last three months, I have used the existing literature to address some of the particular engineering challenges. For better 3D printing, overhangs should be prevented to avert printing errors, for instance. The wall thickness of a 3D printed object is the second factor to take into account. It is advised to avoid using extremely large flat surfaces and to provide 3D models rounded edges (Seepersad, C.C., 2014). Additionally, it is crucial to align all model properties (such as perforations, chambers, horizontal walls, etc.) to one of the six primary orientations that is thought to be a sound design strategy for CNC machining in order to get superior machining outcomes in a CNC mill (Wang, K.C, 2014)      

Mr. Grahame Baker has been coaching me about lean manufacturing and process improvement in my first year of the MSc programme. I used lean manufacturing practises throughout my placement, which is a method of manufacture built on the philosophy of increasing efficiency while reducing waste in a production line (Kumar, G.K.K., 2019). I also kept a close eye on the process improvements, which are approaches used by organizations to assess their established procedures and make adjustments in order to enhance productivity, simplify workflows, respond to shifting business requirements, or boost profitability (Clarkson, J. and Eckert, C., 2005). 

As a mechanical design engineer, it is my responsibility to ensure that the products I am fabricating are completely functional, safe, and able to withstand mechanical stresses. Because of this, I employ simulation approaches in one of my ongoing projects (a bike drink holder) to improve safety while minimising weight by employing structural optimization criteria (Park, H.-S. and Dang, X.-P., 2010). In order to create my own radio-controlled car in a cost-effective manner, I have also been striving to follow mechatronics design guidelines (Buur, J. and Denmark, O., 1990).

Fig: Bike drinks holder

Fig: Remote controlled car (source: unsplash)

Finally, working as an intern at Lorro Precision allows me to delve deep into the field of mechanical engineering. My dream comes true when I believe I can conceive of an issue instinctively and solve it with the resources I have. Using engineering judgments, fundamental principles, and a variety of modern software packages propels me ahead to solve an engineering challenge, resulting in a satisfied feeling at the end of the day.

Reference

Seepersad, C.C., (2014). Challenges and Opportunities in Design for Additive Manufacturing. 3D Printing and Additive Manufacturing, 1 (1), pp.10–13.

Wang, K.C, (2014) Optimal high-rigidity structure design for CNC machine tools using CAE technique. Engineering Computations, 31 (8), pp.1761–1777.

(Kumar, G.K.K., 2019) Understanding the Need of Implementation of Lean Techniques in Manufacturing Industries: A Review. International Journal of Trend in Scientific Research and Development, 3 (3), pp.1083–1087.

Clarkson, J. and Eckert, C., 2005) Design process improvement : a review of current practice. London U.K.: Springer.Park,

H.-S. and Dang, X.-P., (2010) Structural optimization based on CAD–CAE integration and metamodeling techniques. Computer-Aided Design, 42 (10), pp.889–902.

Buur, J. and Denmark, O. (1990) A theoretical approach to mechatronics design. Lyngby.

Teybeh, A., Nejad, Mohammad, R., Behbodi and Mohammad Mehdi Ravanfar, (2015) Analyzing Organizational Structure based on 7s model of McKinsey. International Journal of Academic Research in Business and Social Sciences, 5 (5), pp.2222–6990.

Adeani, I.S., Febriani, R.B. and Syafryadin, S., (2020) Using gibbs’ reflective cycle in making reflections of literary analysis. Indonesian efl journal, 6 (2), p.139.

Skinner, M. and Mitchell, D. (2016) ‘What? So What? Now What?’ Applying Borton and Rolfe’s Models of Reflexive Practice in Healthcare Contexts. Health and Social Care Chaplaincy, 4 (1), pp.10–19.

Cairns, T.D., Hollenback, J., Preziosi, R.C. and Snow, W.A., (1998) Technical note: a study of Hersey and Blanchard’s situational leadership theory. Leadership & Organization Development Journal, 19 (2), pp.113–116.

Mccaulley, M.H. (1990) The Myers-Briggs type indicator and leadership. Gainesville, Fl: Center For Applications Of Psychological Type.