Gohar Maqsood | Engineering Portfolio

Project leadership

Planning, supplier coordination, commissioning and workforce readiness.

Production equipment modernisation

Project type: Seven-figure CAPEX and production automation project.
My role: Proposed replacing three ageing production machines with one more capable CNC machine; engaged operators, supervisors, management, design and quality teams; led supplier selection, delivery coordination and commissioning. Developed training material, trained staff and oversaw preparation of operating procedures.
Techniques: Technical specification, supplier evaluation and negotiation, budgeting, project planning, responsibility allocation, resource levelling, stakeholder and risk management, contractor oversight and lessons-learned reporting.
End result: Commissioned and handed over the machine and automated parts collection system, completed PPAP for all three products, trained staff and shared project lessons learned. Automated parts collection removed the need for continuous operator attendance while the machine ran and reduced the labour required to operate it. Manufacturing and scrap-cost analysis forecast payback of the full project investment within six months, followed by approximately £500,000 in additional parts-manufacturing savings over the next six months. The project increased manufacturing capacity and was designed to reduce scrap costs and overtime. Contractor work was completed with zero reported accidents.

Engineering projects

Selected examples of project scope, individual contribution, methods and measurable results.

NPI and manufacturing readiness

Project type: Introduction of new production equipment.
My role: Led engineering work from equipment introduction through production readiness.
Techniques: Process planning, risk identification, mitigation and transfer, cross-functional coordination and KPI tracking.
End result: Met 100% of project KPIs and eliminated or transferred 70% of identified open risks.

Automotive NPI and process capability

Project type: High-volume automotive component introduction for a Tier 1 supplier.
My role: Worked from feasibility and manufacturing cost assessment through tooling design, manufacture and development; recommended a material specification change based on engineering calculations, then led process validation and production handover.
Techniques: Manufacturing and tooling cost analysis, engineering calculations, tooling development, PPAP, statistical process capability analysis in Minitab, FMEA, control planning, work instructions and staff training.
End result: Centred the process and secured approval after capability studies across selected profile and dimensional characteristics; the lowest achieved Cpk was 1.73, with most results around 2.0. Prepared production staff with documented controls and training.

Versatile metal-forming capability

Project type: NPI manufacturing capability and capital cost reduction.
My role: Conceived and developed versatile tooling, adapted an existing machine and commissioned the resulting manufacturing process.
Techniques: Tooling design, machine modification, process trials, PPAP approval and operator training.
End result: Enabled production of several product shapes to the required quality and avoided purchase of four dedicated machines. Achieved £350,000 in net NPI savings after tooling and machine modification costs.

Rebuild Machine Authorisation workflow

Full process lead time per RMA project

Before299 h

After79 h

Rounded values shown; underlying analysis: 298.58 → 79.45 hours.

Project type: RMA document processing improvement
My role: Led the project through the DMAIC stages, from analysing delays to implementing and controlling the revised process.
Techniques: SIPOC, Pareto analysis, value stream mapping, measurement and capability analysis, root-cause and hypothesis testing, FMEA, cost analysis and a revised standard operating procedure.
End result: After implementation, measured a reduction in full process lead time of approximately 219 hours (73.4%) per completed RMA project, with approximately £12,000 saved per project based on a full cost analysis.

Cropping die improvement

Project type: Continuous improvement of production tooling.
My role: Developed and implemented a cropping die improvement.
Techniques: Root-cause analysis, tooling review and production trials.
End result: Measured a 10% productivity increase and a 25% reduction in component cost after implementation.

Automated material feeding improvement

Project type: Quality improvement for an automated metal-forming process.
My role: Led the 8D investigation, redesigned the automated material feeding system, removed the existing system and installed and commissioned its replacement.
Techniques: 8D problem solving, root-cause analysis, mechanical design and commissioning.
End result: Confirmed the quality issue was resolved in production, with £76,000 in projected annual savings including reduced setup scrap. Lower downtime labour and nonconformance costs were additional, unquantified benefits.

Capital equipment sourcing and development

Project type: Continuous improvement and CAPEX.
My role: Led supplier selection, negotiation, engineering design support, commissioning and delivery to sites in the UK, Mexico and Poland.
Techniques: Supplier development, CAD design, roll-bending engineering and project management.
End result: Delivered five machines for £125,000 in total, including shipping, installation and commissioning. The equivalent UK supplier quotation for the same scope was £450,000, yielding a £325,000 one-time purchase saving.

Chemical blackening process improvement

Project type: Process engineering and quality improvement.
My role: Investigated part rejections, consulted suppliers and developed material-specific procedures, work instructions and a defect catalogue.
Techniques: Process research, supplier consultation, procedure development and incoming and outgoing inspection criteria.
End result: After adopting the revised procedures, reduced part rejection and achieved £18,000 in annual scrapped-part replacement savings. Nonconformance handling and manufacturing delay costs were excluded.

Composite veil production reliability

Project type: TPM and reliability improvement for CNC composite veil manufacturing equipment.
My role: Analysed daily MES/OEE reports, prioritised causes of line stoppages and coordinated production, maintenance and suppliers through modifications, commissioning, procedures and training.
Techniques: OEE analysis, cross-functional problem solving, supplier coordination, commissioning and SOP development.
End result: Resolved recurring equipment issues and measured a 70% reduction in breakdowns in the first month after the modifications.

Mechanical design

Design and design-review work across equipment, mechanisms, tooling and assembly.

Automated window-cleaning robot: movement and actuation

CAD views of a movement and actuation system with cylinders, joints and suction feet at several proposed movement positions — Movement and actuation system independently conceived and designed as an MSc Engineering project contribution.

Project type: MSc Engineering design project for a proposed automated high-rise window-cleaning robot.
My role: Researched, conceived and independently designed the complete movement and actuation system as my contribution to a wider project. Planned and managed my work to meet the project deadline.
Techniques: Engineering research, functional design, 3D CAD modelling, calculations, simulation, DFMEA and project scheduling.
End result: Validated the proposed system through calculations and simulation, completed the design on time, and documented the work in a project report.

Bearing housing redesign

CAD view of a redesigned bearing housing with a bearing and retaining component shown separately

Project type: Mechanical design and equipment reliability improvement.
My role: Redesigned and commissioned a bearing housing for a space-constrained roll-forming machine; researched and sourced a more suitable bearing.
Techniques: 3D CAD design, component selection, supplier sourcing and commissioning.
End result: Addressed a bearing reliability issue, with £4,000 in projected annual bearing replacement savings. Downtime, maintenance labour and schedule effects were excluded from that figure.

Universal inspection fixture

Two CAD views of an earlier product-dedicated inspection fixture — Earlier dedicated fixture

Project type: Adaptable fixture for Equator and coordinate measuring machine (CMM) inspection.
My role: Designed and commissioned a universal inspection fixture for products of varying shapes.
Techniques: Inspection fixture design, adaptable workholding and commissioning.
End result: Covered a current range of 200 products without buying 200 dedicated inspection fixtures, and achieved £68,900 in observed annual fixture cost savings after implementation.

Rotary part-marking equipment

Project type: Production equipment redesign
My role: Redesigned a rotary part-marking solution.
Techniques: Mechanical design, equipment review and production trials.
End result: Reduced consumables cost by 80%, measured after the redesigned system was put into use.

CNC machine assembly planning

Project type: In-house machine manufacturing and assembly planning.
My role: Checked machine designs and planned the assembly flow for equipment built in-house by a manufacturer of machines and parts.
Techniques: NX12, design checks, assembly-flow planning and factory-layout work.
End result: Delivered an approved layout that made machine builds easier and improved the assembly workflow.

Mechanical Design Capability

Selected CAD views of mechanical design work. Further context is available in an interview.

CAD rendering of a mechanical assembly with adjustment handwheels — Mechanical assembly

CAD rendering of a perforated plate — Engineered component

CAD rendering of a base with a circular feature and several supports — Fixture design

CAD rendering of a circular housing — Circular housing

Approach

From an operational need to an implemented engineering solution.

Identify the need · assess technical and delivery risks · work across engineering, production, quality and suppliers · verify the result in operation.