Software Developer at MSS International AG (2022-01 – Present)
Professional software development experience at MSS strengthened programming, systems analysis and debugging capability, applying the same investigative discipline from my engineering background to a new domain.
- Developed backend services and REST APIs using Java, Spring Boot and Maven.
- Investigated discrepancies between customer legacy COBOL software and its converted Java equivalent, tracing issues to the underlying converter libraries and applying fixes there (including test coverage) to resolve them at source rather than case-by-case.
- Investigated the technical feasibility of migrating a converted system to Microsoft Azure, identifying constraints where the proposed approach could not meet requirements.
- Documented processes and built a knowledge base to support onboarding and knowledge transfer across the team.
Process Engineer at YASA (Mercedes-Benz Group) (2015-01 – 2021-01)
Joined YASA when it was a small, rapidly developing engineering company with fewer than 50 employees, initially focused on low-volume prototype production. Over six years, worked through the company's growth and relocation to a larger facility as manufacturing capability was developed for its first major production programme for Ferrari. My role evolved with the manufacturing operation, covering process development and standardisation, manufacturing risk, measurement systems, equipment investigation, process improvement and automation support.
- Created the first structured production work instructions and manufacturing standards as the organisation moved from prototype work towards production.
- Developed and continuously updated SOP/SWIs and manufacturing documentation as processes and equipment evolved.
- Drove manufacturing improvement investigations from the shop floor, breaking processes down to understand current conditions, operator difficulties, equipment behaviour and sources of waste or instability, then making findings visible to everyone affected.
- Coordinated cross-functional teams across Production, Maintenance, Automation and Testing to investigate and validate fixes, applying Lean Six Sigma / DMAIC methods to more complex, multi-week investigations.
- Applied practical interventions ranging from operator training and improved communication to equipment repair, tooling changes and process redesign, selecting the level of intervention the evidence supported.
- Used Python to automate repetitive data analysis and support engineering investigations.
- Facilitated DFMEA sessions during product development, acting as the mediator between specialists from different engineering disciplines to systematically surface design risks and mitigations.
- Supported monthly customer-facing design reviews where DFMEA progress formed part of product development discussions, including for the McLaren Artura and Ferrari programmes.
- Ran regular PFMEA meetings as production processes and shop-floor layouts developed, using the discussions to establish improvement priorities and inform equipment design and procurement.
- Trained on the company's new Mitutoyo CRYSTA-Apex CMM and was the sole person capable of programming and operating it for around two years, personally creating measurement programmes, running measurements, analysing data and producing reports.
- Established internal practices for measurement and reporting based on engineering drawings and GD&T requirements.
- Became a reference point for CMM programming and measurement strategy as the capability expanded, advising design engineers on measurement capability and realistic tolerances.
- Set up and commissioned new manufacturing equipment as production volumes increased, including both in-house builds and supplier deliveries.
- Investigated and tuned equipment to resolve machine behaviour issues once in operation, working with equipment manufacturers and software providers when necessary.
- Populated the company's CMMS with machines, spare parts and checklists, building preventive maintenance schedules from manufacturer-recommended service intervals, and contributed to shaping the structure of the company's OT equipment database, supporting traceability.
Process Engineer at Autoliv (2012-01 – 2015-01)
Process Engineer in high-volume automotive seatbelt manufacturing within a mature, safety-critical production environment, certified and audited to IATF 16949 and ISO 9001, focused on production stability, quality, engineering changes and day-to-day manufacturing problems.
- Monitored production KPIs, ran 5S audits and trained operators on standardized-work updates, and responded to day-to-day manufacturing problems affecting process performance.
- Investigated customer complaints and quality issues using structured root cause analysis, contributing the production-process perspective to 8D investigations.
- Investigated barcode and QR-code readability issues reported by customers as part of an 8D investigation, identifying the effect of older customer reading equipment on print contrast, and improved laser and label-printing quality accordingly.
- Coordinated engineering changes across Production, Maintenance, Automation and Logistics, including equipment and documentation updates, and collected evidence from production trials to confirm successful implementation.
- Worked with Automation and Maintenance teams on the introduction of computer-vision inspection for quality control.
- Provided production-process input to a controls-engineer-led rollout of 100% visual inspection at final check, scheduling machine availability with production and updating process documentation once validation was complete.
- Managed production of legacy products by locating relevant documentation and superseded equipment, identifying the appropriate production line and coordinating preparation and clean-up for these one-off builds.
