CDR Questionnaire Form

Name: Amir Khan

Career Episode No: 1
Selected Engineering Occupation: Mechanical Engineering/. Industrial/ Production

Name of the Project Design and Installation of an Automated Assembly Line

(Note: You should mention name of
the project you worked on not your
job title)
(Example: Installation of ABC
Transformer, Design of Commercial
Complex DEF, Construction
Supervision of Residential Building
GHQ)
Project Start Date: January 2021
Project End Date: December 2021
Location of the Project: XYZ city
(Note: The place/area where the
project was carried out)
Name of the Organization: ABC Manufacturing Ltd.
Position Occupied by you: Mechanical Engineer
Project Overview: The project aimed to design and install an automated
(Please mention overview of the
project you are involved in and
assembly line at ABC Manufacturing Ltd. to enhance
describe the nature of your productivity and efficiency. My engineering work focused on
Engineering works) developing mechanical designs, overseeing the installation of
automated machinery, and ensuring the integration of these
systems into existing workflows. This included creating
detailed 3D models and engineering drawings, conducting
simulations, and performing stress tests to validate design
robustness. I collaborated with electrical and software
engineering teams for system integration, established quality
control protocols, and developed standards for installation,
modification, testing, and maintenance. The successful
implementation of this project resulted in a 30% increase in
production efficiency and a 15% reduction in defect rates,
demonstrating significant improvements in both productivity
and product quality.
Organizational Hierarchy: As a Mechanical Engineer, I worked during the project under
(Note: Your work position while
working in the project, whom were
the Senior Mechanical Engineer, who had to oversee the
you supervised by, whom did you junior engineers and technicians. The complete chain of
supervise, the complete chain of command was as follows: the Project Manager was the
command for the flow of overall in-command person, the Senior Mechanical Engineer
instructions/work)
took care of me with supervision and advice, I was in
command/ directed the junior engineers and technicians, and
we interacted with the electrical and software engineering
CDR Questionnaire Form
teams for integration. This is an excellent hierarchical
approach with adequate instruction flow and smooth project
implementation.
Responsibilities Responsibility 1: Project Initiation works
(Note: Include five responsibilities,
the responsibilities should be relevant
to the engineering
position/qualifications that you seek
assessment for, the responsibilities
you include here should be technical
especially focusing on your
engineering work rather than daily
office work or managerial work that
comes along with the job, highlight
the responsibility and elaborate each
responsibility in a paragraph)

**Note: Refer anzsco code 233512

for Mechanical engineer ) Link
Below:

--https://www.acacia-au.com/
anzsco/233513.php
At the beginning of the automated assembly line project, I
played a pivotal role in project initiation. I started by holding
detailed meetings and discussions with clients to learn more
about their requirements, expectations, and specific objectives
for the new assembly line. I gathered detailed information
regarding the project's functional statements, organizational
charts, and existing workflow documentation to build a deep
understanding of the current processes and constraints. I
collaborated with the team in identifying the approach to the
project and dividing work based on individual strengths and
needs about the project. This has comprised milestones, set
timelines, and defined deliverables. I created a very detailed
project plan, outlining the different phases of design,
installation, and testing. I also managed communication
among the other departments: electrical engineering and
software engineering, such that the mechanical systems could
be combined with automation controls. I also conducted a
preliminary analysis to identify potential challenges and risks
associated with the project, thus developing mitigation
strategies. A structured approach at the project initiation
phase in detail is crucial for setting a solid foundation that can
ensure successful project execution for all projects to be
achieved based on the set client goals and objectives, within
schedule, and by effectively utilizing resources.
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(It may include work division, methodology determination, Information
collection, meeting with clients, studying functional statements, organizational
charts and project information)
Responsibility 2: Parameters determinations

It was, therefore, a critical design and installation of the

automated assembly line to find out what the essential
parameters are. I commenced with making the design
assumptions and considerations regarding load capacities,
stress limits, and material properties to ensure the system's
robustness and reliability. After these assumptions, I made
extensive calculations and simulations concerning the fact
that mechanical components could handle operational
stresses. For the production process, I studied existing levels
of productivity and efficiency at work. This required the flow
process chart of the existing plant layout to identify
bottlenecks or general inefficiencies that automation would
correct. I developed an improved plant layout for the new
assembly line, including required space for machines and
safety zones, and workflow improvements. I also created
work measurement programs by analyzing work samples to
develop labor-requiring standards. It was through this
analysis that I set the benchmark for productivity and ensured
that the new system could efficiently yield desired output
levels. By carefully determining these parameters, I ensured
the automated assembly line would be designed to enhance
productivity, optimize workflow, and maintain a high
standard of labor efficiency.
CDR Questionnaire Form
(Design assumption, consideration, and calculation if done.)
( For Production process, determination of Production process, productivity,
workflow, Plant Layout, establishing work measurement programs and
analyzing work samples to develop standards for labor utilization )
Responsibility 3: Design works

In the design of this automated assembly line project, more

emphasis is put on the provisions of mechanical equipment
and systems with built-in reliability to ensure the performance
of quality production. I have designed numerous components
integrated into the assembly line, such as conveyors, robotic
arms, and fixtures, to meet functional and safety operational
requirements. I have developed detailed 3D models and
engineering drawings for each component using CAD
software to detail features for exact manufacturing and
assembly. I worked closely with electrical and software
engineering to unify control systems into mechanical design
for coordinated operation. At this stage, I had determined
where productivity could be increased by analyzing current
workflow and locating any bottlenecks. I carried out design
enhancements like conveyor speeds and robotic arm
movement improvement to reduce cycle times as well as
increase throughput. I also designed quality control aspects in
the terms of automated inspection stations for defect detection
and elimination at the onset of the production stages. These
design changes upped the assembly line's productivity by
30% in total and also helped in improving the product quality
all the more by causing a 15% drop in defect rates. Designing
such comprehensive additions assured me that my final
assembly line would cater to all the efficiency and quality
CDR Questionnaire Form
demands of the client.
(Designing mechanical equipment, machines, components, products for
manufacture, and plant and systems for construction)
(For Production process, Identification of improvement area for the increase
of productivity and quality of the product)
Responsibility 4: System Analysis

As part of the project to realize this automatic assembly line, I

conducted practical system analysis to verify penetration and
design reliability. This encompassed performing
comprehensive reviews of the mechanical designs, with
simulations proving performance under numerous operating
conditions. In addition, finite element analysis was utilized to
assess stress distribution and deformation in critical
components to ensure the non-occurrence of failures due to
operational loads. I established thorough standards and
procedures to guide the construction, modification, and
maintenance of the facility that housed the assembly line. The
procedures were meant to ensure that the construction,
operation, and maintenance was carried out in conformance
with engineering principles and safety standards. I developed
quality control methods that spelled out test methods and
inspection processes to maintain uniformity in the quality of
products. During the analysis phase, I collaborated with the
quality assurance group to carry out rigorous test procedures,
which consisted of tests of loads and endurance tests. This
enabled us to identify likely issues and permitted us to make
modifications before full implementation. I also crafted
maintenance schedules and inspection routines to ensure that
the system functioned durably and dependably. Setting those
guidelines and carrying out a critical system analysis will
CDR Questionnaire Form
guarantee that the automated assembly line operates with high
efficiency, safe operation, and minimal downtime.
(Analysis of the design, Mention the process of analysis, establishing
standards and policies for installation, modification, quality control, testing,
inspection and maintenance according to engineering principles and safety
regulations)
Responsibility 5: Results or Outcomes of the Project
After completing the automation project of the assembly line,
I concentrated on the plant buildings and equipment's overall
maintenance to derive maximum utilization and life. I had
new designs and surveys developed within my direction and
integrated into the system to constantly conform to the
improved productivity aims. I developed comprehensive
maintenance schedules, having written descriptions of routine
inspections and procedures for preventive maintenance
measures to reduce downtime and increase the longevity of
machinery. Some of these involved making regular checks of
the critical parts, lubricating moving parts, and calibrating
automated systems to maintain accuracy. In implementing
such a maintenance strategy, we have realized an outstanding
reduction in cases of surprise breakdowns and a cut in
maintenance costs. The automated assembly line has
increased production efficiency by 30% and lowered the
defect rate by 15%. The improved workflow and quality
management practices worked toward a better quality product
and, therefore, customer satisfaction. Other project benefits
that accrued, including operational efficiencies with a more
efficient use of labor and better inventory management; the
success of this project indicated that careful planning, good
detail in design, and rigorous maintenance could improve
business processes.
(directing the maintenance of plant buildings and equipment, and
coordinating the requirements for new designs, surveys and maintenance
schedules)
Other Responsibilities:
Besides my main task, I was actively involved in several
other critical activities. I used to meet with clients,
stakeholders, and senior employees regularly, where I
presented the project's progress and got their feedback. These
meetings were used for providing clear communication and
resolving any issues that may arise on time conducted
economic and environmental impact analyses within the
feasibility of the project. This included analyses of the
economic feasibility of an automated assembly line and
environmental benefits in terms of waste reduction, energy
CDR Questionnaire Form
usage, and others. I have decided on the material flow, the
inventory levels, and other productivity measures needed for
the manufacturing process to make it most efficient. This was
accomplished by looking at the current inventory
management systems, determining deficiencies, and devising
solutions to utilize materials better and eliminate waste. I also
closely coordinated with various departments, including
procurement, quality assurance, and logistics, to ensure a
smooth integration of the new assembly line within the
company. This interdisciplinary work is the prerequisite to
the project's success as it allows an integral approach to
solving problems and optimizing processes.
 Meeting with clients, stake holders, senior employee
 Economic/ environmental impact analysis of project
 Determination of material flow/ Inventories and productivity
 Coordination with different department within the organization

Technical Difficulties During the automated assembly project, I encountered several

(NOTE: List the technical difficulties
that you faced while working in the
technical issues that needed immediate checking. Prime
project, the problematic situation amongst them was a design problem discovered in the early
might be design fault, system break prototype of the conveyor system, surfacing as a
down or any other technical misalignment and inefficiency in the operation. This called
malfunctions, along with this
problem, provide the approach you for a detailed root-cause analysis of the weaknesses within
provided for solving this difficulty) the support structures and alignment mechanisms. All these
were redone by me, validated with the enhancements in the
simulations, and the changes brought about, which gave the
machine a stable and efficient conveyor system. Another
considerable problem had been with the mechanical systems
being integrated with the control software. Hence automation
delays taking place. I worked very closely with the software
engineering team on designing better communication
protocols between hardware and software. We also held co-
testing sessions for troubleshooting and solving all integration
problems to ensure synchronized and smooth assembly line
operation.
Also, we had unexpected problems with material handling
due to variations in the sizes and weights of the components. I
used adjustable fixtures and flexible handling mechanisms to
cater to these variations. Many test runs were taken to
optimize the handling process for different component
specifications, such that finally, it became reliable and
repeatable. The expected unexpected breakdowns did occur in
the early phases of the testing. Still, from this, I learned that
CDR Questionnaire Form
with appropriate preventive maintenance, as well as ensuring
the training of team members in the modified protocols,
downtime could be significantly reduced within further
processes. Defined proactive approach substantially
minimized downtime and allowed continuous operation. Such
detailed analyses, collaborative efforts, and innovative
solutions proved to be workable in completing the work and
realizing the automated assembly line implementation with
success in obtaining the productivity and quality goals of the
project.
Note:
 Responsibilities should contain detail information about the engineering activities that you performed which
should be sufficient enough to demonstrate your engineering and technical skills as an engineer.

 Technical difficulties is the area where you have to demonstrate your problem solving skills technical as an
engineer. The solution to these problem should technical and demonstrated the engineering activities rather than
the managerial work.