Design Services
With a flexible, proactive approach Matchless Design Ltd provides design services across the entire product development cycle from initial specification writing to manufacturing drawing completion and part order placement.
For each design service I have tried to summarise my approach and appropriate experience.
Having worked in a broad range of companies and industries I can adapt to your company's needs and apply an appropriate level of design assurance.
Specification Writing
This is very much a two-way dialogue and could be anything from an outline summary for a limited package of work to a full design specification. Generally it consists of absolute requirements and "nice to haves" to provide some flexibility. I write a design specification as solution free as possible taking account of project time constraints.
Concept Design
With experience I spend more time on this stage of a project, trying to create as many options for consideration as possible and finalising the agreed concept design. Earlier in my career I would rush this aspect and then spend significant effort forcing the design to work and sometimes having to revise the original design.
Depending on the project some scoping calculations and meetings with potential suppliers may be necessary to reduce the likelihood of design issues occurring in the subsequent detail design and drawing phases.
Detail Design
During this phase the 3D model is finalised to include as much detail as possible. Features such as machining rads, lead-in chamfers and clearances to allow for machining tolerances will be incorporated. This will involve liaison with production engineers or suppliers to ensure manufacturability and resolve potential issues such as fabrication distortion or casting porosity.
Scoping Calculations
I use Mathcad to perform scoping design calculations such as stress analysis or fluid flows during the concept and detail design stages. These may be required for design reviews and risk assessments. I have a number of text books and design documents that I reference for these calculations.
Design Checks and Review
Checking and reviewing is essential to a successful design. Each company has a different approach dependent on the industry and customer expectations. I have checked designs against stringent customer requirements, tick box lists and in a less structured environment and have chaired, and participated in, formal and informal design reviews.
At Babcock I was responsible for the design check of CAD models and design documents for a section consisting of 9 engineers prior to a formal design review by the Chief Engineers.
Drawing Creation and Checking
I was taught to produce engineering drawings on the boards at Renishaw to BS308; I now use CAD and BS8888 but the fundamentals for clarity and unambiguity remain the same. I have experience of creating a design set-out (DSO) for external drawing production, supervising drawing creation by others and producing drawings from my designs. I can provide an independent drawing check and, when necessary, can check my own drawings.
In 2020 I attended an excellent 3 day Geometric Tolerancing course by Iain Macleod Associates Ltd (Chair of BSI BS8888 Technical Committee).
Risk Assessments and HAZOP's
I have chaired and participated in Risk Assessments (BS EN ISO 12100) to meet regulatory requirements as part of a formal review process. I have participated in HAZOP reviews of designs in the process and nuclear industries and have experience of applying Machinery, Pressure Systems and ATEX directives.
Manufacturing Liaison
I pride myself on my liaison with manufacturing engineers and external suppliers. When feasible I prefer face to face discussions because these can draw out potential solutions that may not be apparent in on-line communications.
I have direct experience of precision machining (inc one-hit), welding and fabrication, casting, sheet metal (inc riveting), surface coating, hardening, moulding and 3D printing.