Marc Buckland

The RPD area involved many functions which were mostly learned on the fly with assistance. Key work included; 3D printing (Renishaw Alluminium, Eos SLS and Markforged), Woodwork, metal work, plastics and various glues and substances, then more recently CAD (tebis) and CNC machining for prototype parts and also area/equipment support within the Dunton campus.

• Monitored inventory, machines, tools and equipment to reduce project delays.
• Maintained safety protocols while ensuring cost-effective and safe handling of printing and machining equipment and materials.
• Supplied products according to changing daily work orders and specific customer needs.
• Used problem-solving and issue-resolution skills to promptly and successfully address production problems.
• Organized and prepared workstations and materials needed for operations to maximize productivity.
• Investigated processing errors and malfunctions, resolving issues with minor machine repairs.
• Inspected products and machines to maintain quality and efficiency.
• Measured and cut materials in adherence to schematic drawings.
• Proactively managed projects to ensure customer satisfaction for custom work.
• Used 3D CAD tool Tebis to design, develop and produce high-quality models.
• Produced sketches and diagrams to illustrate design concepts.
• Passionate about learning and committed to continual improvement.

Day to day responsibilities of running and operating a test cell vary immensely and include:

• Acquired and ‘on the job’ progressive knowledge of prototype engine, system, equipment and components.
• Tackling challenging new projects involving brand new engines, parts and equipment designs.
• Regular and routine maintenance of the cell and equipment. This includes weekly Dyno checks, Cell calibration records for equipment such as exhaust gas analyser equipment, cylinder pressure transducers, pressure and temperature monitoring equipment and Turbo speed sensors.
• “Self-management” to relay information regarding the engine, cell and test equipment to programme engineers and test techs. Work with test technicians and engineering team to meet time and quality driven goals and complete work requested.
• The everyday running of the test cell. Liaising with the engineering team to find the most efficient way to run the desired test programme.
• Day to Day housekeeping of the cell and ensuring it is in a clean tidy and safe state to run. This includes making sure cell is ISO 14001 & ISO 9000 compliant, that waste materials are disposed of in a safe and correct manner, test equipment and engine parts are stored and labelled correctly.
• Using automated software. Running testing using automated running tools such as CAMEO and Autotest. Also using software used by these systems such as PCMASAP, EEI and MEI links and Vision Recorder Controller.
• Pre running and daily visual checks and maintenance of the engine and test equipment. Ensure the engine has correct oil level, and is in a fit state to run. This requires visual inspection of the engine and its ancillary devices, pressure and temperature thermocouples, and external test equipment such as monitoring devices, oil or coolant skids and plant coolant devices ensuring technical excellence and high standards.
• Daily calibration and routine checks and maintenance of smoke meters, blowby meters and exhaust gas analyser equipment including filter and paper changes.
• Undertaking all mechanical work and fault finding required by the engineering team. This can range from servicing and routine spec changes to cylinder head changes. Complex fault finding work undertaken alone or with the supervision of an engineer using equipment such as boroscope, cylinder pressure measurement equipment and gas pressure check.
• Installation and removal of Dyno and cell wiring harnesses and fault finding on faulty looms.
• Complete mount and dismount of engines either in cell or pallet out. And the equipment relevant to each test as specified by the engineering team.
• The running of manual testing such as Full load curves, max torque capability work, Durability and ageing tests, component prove-out, PCM data capture emulation and manual running of certification work.

New toolroom (new builds), toolmaker + group leader role and also time in the Machine shop and "old" toolroom (DIE repair)

• Similarly to the Dyno area, communication/liaising between supervisor, CAD teams, tech engineers, managers and other areas. Respectively, ISO and Ford quality standards to adhere to.
• Role: The manufacture of tooling DIE’s for stamping body panels.
• Group leader role; Organise and hand out work to team, liase for progress reports to relay to next shift. Organise and prepare requests for machining or materials required.
• Continuous and applied use of technical & engineering drawings, CAD layout and blueprint prints to adhere to.
• Strong comprehension of Isometric drawing, Multiview, dimensioning, perspective projection and cross/half sectional views.
• Working to Scale and tolerances, within time constraints utilising methodical work practices to achieve maximum output
• Working to customer demands with projected timeline and deadlines, incorporating DIE manufacture changes on the go as and when required and finding solutions to engineering faults such as casting errors, breakages and machining faults
• On the job ‘toolbox talks’ and separate supervisor/group leader meetings to address new designs and/or issues arising to ensure time and labour allocation for possible new practices and processes to meet both customer demand and technical excellence.
• Supplying engineering drawings to machine departments for DIE components required.

Also, Old toolroom (Die maintenance), toolmaker + group leader role

• Role: Similar to above, but the main role is to fix dies that come in from the press shop production line ensuring a quick turnaround during a line stoppage breakdown or organising and executing scheduled maintenance as required.
• Monitored production and made improvements for quality and productivity.
• Managed proper storage, handling, and labeling of hazardous materials.
• Requisitioned replacement tools, parts, and equipment.
• Read and stuck to detailed production schedules.