AAC/04/12/05

Academic Assessment:
Career Learning Assessment Form CEng
Manufacturing Exemplar

Following an initial assessment of your academic qualifications and career history to date, it is
possible that you may be able to demonstrate sufficient evidence that you have satisfied the
equivalent of the academic requirements for registration as a Chartered Engineer. This is shown
through a combination of your formal academic and work-based learning. You are therefore being
asked to complete this form and provide more detailed evidence relative to your work based
learning to allow a full assessment to be made.

1. PERSONAL DETAILS

Surname: Manufacturing / Process Industry Forename(s)

Title: Date of Birth (DD/MM/YY):

Street Address:

Town/City: County/State:

Postcode: Country:

Home Telephone No.: Mobile No.:

Email:

Are you currently a member of IMechE? No Yes Membership No.:

To meet the requirements you need to demonstrate that you have achieved a level of knowledge and
understanding equivalent to that of a graduate with an accredited Masters degree. It is important to
appreciate that this is about knowledge and understanding (broadly, the practical application of knowledge).
Someone with Masters Level knowledge and understanding will have a good grasp of the theoretical principles
underlying their particular area of engineering practice. They will be able to apply them in novel, unusual or
complex situations where codes or procedures are unavailable, or do not meet the full requirements.

FORMAL QUALIFICATIONS If you have more than three qualifications provide details (as below) on a separate sheet

Start
Qualification Nature of
Entry Year and Duration
Subject/Discipline Academic Establishment Title Study (eg
(eg yr 1) Finish of Study
(eg HND) full time)
Years
1st Qualification HNC Part-Time Year 1 1990 2 Years
Mechanical / Manufacture 1992

2nd Qualification

CEng CLA v10 Feb 13 1

3rd Qualification

Engineers with different career profiles and experience may be able to demonstrate their level of knowledge
and understanding in different ways. The questions below are intended to act as prompts to draw out the
necessary evidence in the form that is most likely to be appropriate. The key is to identify appropriate
evidence in your personal situation, especially evidence of the deepening of your technical knowledge
and understanding in your own field of engineering, beyond that expected of a graduate with a
Bachelors. Since you have been asked to complete this form, it is likely that your non-technical knowledge
and understanding will have been developed to a satisfactory extent and, while we ask for confirmation of
this, it is not the focus of the assessment. The crucial aspect is your technical development to a level
equivalent to Masters Level.

You are strongly advised to read the guidance notes that accompany this form.

Please note: This is not an assessment of professional competence gained in the workplace. On completion
of the CLA process you will be advised of the requirements for the Professional Review assessment stage.

NB: The boxes on this form can be expanded. The size of the box provided is not indicative of the amount of
information required. As a guide, please aim to provide at least half a page per section and limit your
response to a maximum of one and a half pages per section.

1. In what area(s) of engineering practice would you regard yourself as

SPONSORS
specialising, and how have you acquired and maintained the technical knowledge
INITIALS
and understanding needed to be skilled in these areas?
Projects that I have managed range from several hundred to several million pounds both in
the UK and South Korea.

I have progressed from Apprentice to Engineering Manager and thoroughly enjoy practicing
my knowledge, learning and helping to develop others.

The principles and foundation of my engineering knowledge came from my HNC in

Mechanical Engineering, coupled with my 5 year technician apprenticeship and subsequent
courses throughout my career.

During my 14 years working in the Paper Industry I have used my knowledge in areas such
as

1) Pull out forces for the design of machine foundations.

- Example. During my consultancy work for Proctor & Gamble I designed the fastener
method for holding down 650 kW DOL motor driven vacuum pumps through reduction
gearboxes. This was a particularly difficult problem since the gearboxes had to be mounted
on top of an existing concrete vacuum flume of limited depth. I had to model this through
AutoCAD and take into consideration the restricted depth and limited mounting space. Due
to limited space and depth of concrete I had to overlap the pull out cone of resistance of
each fastener and take into consideration the weakening effect of doing so.

2) Drive power requirements for paper machines, torque calculations, ratios, input / output
speeds.

- Example. During the removal of line-shaft and installation of 11 sectional drive system I
personally calculated the power and speed required at each point of machine input for
adverse and normal running conditions. Paper Machine 5 (East Lancashire Paper Mill)

3) Fluid Dynamics for pipeline applications, pumping, head requirements.

CEng CLA v10 Feb 13 2

 - Example. During my employment in the paper industry I had to regularly calculate pump
sizes, pipe sizes, pipeline losses, static and dynamic head for new or replacement pumping
systems.

4) Thermodynamics for design of steam systems.

- Example. I personally designed the steam system for Devroniser at Proctor & Gamble
using manual calculations for expansion, springs rates, static weights, sliding and fixed
brackets.

6) Design using AutoCAD

- Example. I use my skills in AutoCAD to design the layouts for the new factory in South
Korea for Tullis Russell. I personally surveyed and measured the detail and subsequently
produced the layout drawings for building modifications and new machine locations.

7) Design using 3D Pipe system software

- Example. At Proctor & Gamble I modelled the area of factory that my company was
developing in 3D using software called Plant Design System (PDS).
This software was extremely useful for showing an interactive 3D environment where the
plant engineers and associates could see what the new layout would look like.
I then used the software to create pipeline cutting lists and manufacturing / installation
detail.

I have endeavoured to both self study and attend courses where required to ensure that I
remain competent to operate as an engineer, suitable to whichever environment I have
been working in.
During my ongoing development appraisals, potential training courses are explored to see
whether they would benefit my current or future roles. Milliken also has online courses that
are specific to my role as a leader that I have to complete during each financial year.
These courses cover aspects such as Trade Secrets, Contract Law, Correct Use of Email and
internal Communication systems, Compliance & Ethics and Code of Conduct.

I have also specialised in planned and preventative maintenance systems using

technologies such as Condition Monitoring of Bearings, Vibration, Thermal Imaging and full
spectrum analysis for complex situations such as gearbox and drive trains.

- Example. I was personally responsible for introducing and implementation of the

Condition Monitoring System at East Lancashire Paper Mill and Tullis Russell Coaters.
In both instances I used a system manufactured by SPM an industry recognised system for
monitoring condition of bearings and predicting failure before unplanned downtime occurs.
We also used the system for monitoring vibration to detect conditions such as out of
balance.
In both instances the systems were responsible for reducing unplanned downtime.

I once presented my experiences and successes at the GEC Manchester during a

maintenance exhibition to engineering professionals and other delegates. This was during
my employment at Tullis Russell Coaters.

I currently operate at Engineering Manager level for Milliken industrials where I need to
apply engineering knowledge on a daily basis to support the maintenance department on
technical problems from calculations to diagnostics.

- Example. I have produced calculations to determine start up and normal running loads on
the boiler system to check capacity prior to installation of new machinery.

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 I am also developing my engineering team member to a higher level of competence,
recently sending him on a Spirax Sarco Steam Maintenance Course.

I have responsibility for:

1) Health & Safety systems for engineering.

2) Implementation of planned and preventative maintenance systems
3) Maintenance of machinery.
4) Research of new technologies to improve process.

- Example. This is not always an engineering problem, for example I have during the
past eighteen months been gathering data to understand why a PTFE coated release
fabric fails to last longer than 2 -3 weeks on our main vulcanising press. The
research involved retaining samples of each panel used in the machine and
analysing under in-house microscope, also using the manufacturer to analyse in the
laboratory what is happening to the coated material. After research we believed that
it was a combination of rubber accumulation at the surface and off-gassing of the
rubber during vulcanising. Many theories continued since this is a real life situation
where mathematics cannot help. The final outcome was actually to change
manufacturer and use a new coated product with what appears to be inferior
surface coating compared to the original. The result is that the product is now
lasting 8 12 weeks therefore improving process reliability. Belief is now that
improving coated surface quality actually impairs the ability to off-gas.

5) Project design and management.

6) Budget control.
7) Environmental management ISO 14001 and EMS.

2. Explain the technical decisions/judgements that you are required to make in

your current post and the underlying knowledge and understanding required to SPONSORS
do this effectively. (If previous posts provide a better example of this, please add INITIALS
information on this).

Current Employment (Milliken Industrials)

As Engineering manager in my current role I have a responsibility to ensure machinery is

maintained correctly to maximise process reliability, whilst also developing the
manufacturing processes with the company to ensure quality, efficiency and improvement
to existing products.
This often extends to development of new processes.

- Example. I have been heavily involved with the LEAN manufacturing drive at my
Plant to improve quality and consistency. I have been involved in the development
of standard work whereby time studies were carried out by small teams on different
machines on site to determine to most efficient and effective way to operate. The
standard work patterns are now in place, associates trained and I personally audit a
process daily against standard. I am personally involved at management level in the
daily 4pm meeting to review audit results, discuss issues and implement action to
improve.

- Example. I am currently working on the engineering aspects of improving our

rubber processing plant by the introduction of technology. The technology is in the
form of rubber extrusion to feed calendar automatically where this is currently a
manual operation. I am currently researching this extrusion technology since I have
CEng CLA v10 Feb 13 4
 previously had no experience in this field.

At Milliken (Walk Off Mat Manufacturer) I am employed to bring a higher level of

competence to improve what was considered as an unacceptable level of process reliability.
I have had to apply my knowledge to determine the reasons for poor reliability of
machinery and offer / present solutions to senior leadership.

- Example. When I joined the business, Downtime due to engineering losses on Z

Press (Main Vulcanising Machine) was circa 5.5%. Virtually no preventative
maintenance was carried out and it therefore in a poor state. Over the last 2 years
and also involving a rewire of the machine and introduction of planned maintenance
the current downtime is now 1.75% overall for last financial year including both
planned and unplanned. Process Reliability is up 8% on last year.

The first issue was reliability of the main vulcanising and pressing machine that on
thorough investigation and assessment of existing issues, I determined that the control
wiring had been designed and installed inadequately for the temperature and general
conditions they were expected to operate within.

I led the project from design principles through to awarding a contractor to completely re-
wire the machine. This involved the use of specialist cables with a combination of Screened
PTFE / Tinned Copper and Silicone Insulated signal cables. The machine consists of a PLC
control system with remote HMI and complicated hydraulics axis control equipment. These
systems were also replaced with equipment of a more suitable standard.

I have gained a greater understanding electrical engineering during my career that I can
now apply from an analytical point of view when solving problems.

Further machines have also been upgraded during my engineering leadership in all
engineering disciplines.

My engineering knowledge and experience also leads me into process support where in-
depth analysis of production issues is required to determine failure modes. This may
involve short to medium term analysis leading to either machine alterations or changes to
process recipes.

Previous Employment (Tullis Russell Coaters)

Two major projects were completed by me during my employment.

1) Closure of Hanley Operation Expansion of South Korean Operation

During this project I operated closely with the Board of Directors to determine the best
approach to closing the existing operation in Hanley and what would be required for
expansion of the Korean Plant.

The expansion of the Korean Operation included the purchase of neighbouring factory that
required major modifications to suit our requirements. I personally managed the pre-
purchase due-diligence including surveying the site and producing AutoCAD drawings of
existing and future requirements. I managed the structural surveyor and ensured the
company followed precisely the Korea Authority Local Regulations.
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 Once the initial due-diligence was completed I presented this to the Board who
subsequently went forward with purchase.

I then continued to project manage the expansion including building modification, joining
to existing Korean factory, specification of new machinery, relocation of machinery from
Hanley, installation of new machinery and ancillary equipment.

2) Expansion of Bollington Operation Finishing Department

To compete in forever challenging markets the company had to reduce costs whilst
improving its efficiency and manufacturing quality / capacity.

My role was to redevelop the finishing department by installation of semi-automated

packaging machines and new sheeting capabilities.

The project included the specification of new power operated guillotine, new precision
sheeter and packaging equipment.

I worked closely with the company and suppliers to specify new machinery and overall
requirements.
In particular I had to work extremely closely with the chosen American Sheeter supplier
not only on the complicated purchase contract, but also on the UK Health & Safety
Requirements for this type of equipment. I spent time in the USA advising and analysing
each part of the machine to ensure it was designed to exacting standards to meet our H&S
Regulations prior to build with the suppliers design engineers.

Previous Employment (Millwide Engineering) Consultants to the Paper Industry

I was employed to design and manage modifications to the Proctor & Gamble Tissue
Manufacturing machine at Trafford Park Manchester.

The project was to upgrade and modify the machine to be able to produce Charmin Brand
of Papers onto a machine designed to manufacturer Bounty Brand of Kitchen Towel.

My role was to:

1) Design using 3D modelling the existing plant and required modifications.

2) Produce engineering drawings and required calculations.
3) Calculate pull out forces for foundation design.
4) Calculate power and loads for new vacuum system.
5) Design and calculate vacuum system for new wire table equipment.
6) Design and produce drawings for complex steam system to Devroniser.
7) Manage installation and team of contractors.

Previous Employment (East Lancashire Paper Mill)

My major achievement was the upgrade of the stock approach system and No5 Paper
Making Machine. My involvement was:

1) Produce initial project scope and budget quotations.

2) Work with senior leadership to gain approval for expenditure.
3) Specifications for alterations to Automatic bale handling system.
4) Specifications for new pumping systems throughout stock approach system.
5) Specifications for new thin stock cleaning system.
6) Specifications for additional wire drainage system.
7) Specification for new Dandy roll system for water marking.
8) Specifications and calculations for removal of line shaft and installation of new 11
section DC Drive System SCADA control and fibre optic control link technology.
9) Replacement of after dryer system for higher rated drying performance

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 The project was circa 3.5M with all project management completed in-house to reserve
funds and maintain local knowledge. I worked closely with all multi-skilled disciplines within
the company whilst being personally responsible for overall project management.

In my opinion this project is where I really started to exercise my engineering knowledge

and became a respected engineer with the Paper Industry.

3. Give an example (or examples) where you have used your underlying technical
SPONSORS
knowledge and understanding to develop a solution to a novel, unusual or
INITIALS
complex situation.
Year 1999 (East Lancashire Paper Mill)

As part of a major upgrade of No5 Paper Making Machine the company needed to decide on
how they were going to provide the drive for the machine at higher speeds.

I was given the engineering problem of providing a solution.

The background was that machine was driven by a line shaft using one DC Drive motor,
line shaft driving with 11 sections of the machine through pulleys, and individual gearboxes
at each take off section.
I looked at two solutions.

1) To upgrade the existing line shaft and install new gearboxes at each section.
2) To replace the line shaft system with individual drives at each section.

1)

I used industry standard formulas and calculations that I had learnt through experience
and from attending Beloit Walmsley courses. Once critical speeds data and calculations
were established for analysing each section, I generated an excel spreadsheet where I
could easily input the characteristics of each section of the machine. This then calculated
the suitability of existing pulleys for the new duty.
It became clear at the onset that the existing pulleys and sectional details were not capable
of running at higher speeds under greater loads.

2)

Using training material gained during short courses with Beloit Walmsley, I proceeded to
calculate the drive power and speed requirements for each section of the machine. This
was a complex situation since some of the sections consisted of steam fed drying cylinders
that could potentially flood if the internal siphon failed to function correctly. This required
calculations for both normal load and flooded load. Of course calculations were also carried
out for starting loads under normal or adverse conditions.
It was an important factor in the drive designs to take account of adverse conditions since
paper machines are difficult to stop and start and would be expected to continuing running
with one cylinder or more not functioning correctly.

Through use of correct calculations and industry knowledge I completed the drive
requirements. The drives were eventually purchased and installed with no issues.

CEng CLA v10 Feb 13 7

 Proctor & Gamble Year 2000

1) Stock Tank Installation

During the upgrade of the Tissue Machine I had to design and install a stock holding tank
in the machine house at 1 st floor level. The 1st floor was of a mezzanine construction
although visually strong utilising concrete reinforced sections and piled foundation through
the basement.
The stock holding tank was designed to have a combined static weight of 280 Tonnes when
full and the consultancy I worked for insisted that it had to be sited on the 1st floor.

My first thoughts here were that surely the building foundation were never designed to
hold such weight. I made my concerns heard to my employer who stated they would
request for a structural engineer to visit site. The structural engineer stated that the
existing beams could be upgraded at 1 st floor level with carbon fibre technology. I was
totally bewildered at this point and proceeded to obtain building drawings from Proctor &
Gamble in the background.

On inspection I duly noted that the machine house structure was not designed to hold such
weight and provided calculations to my employer to prove the situation.
The project was stopped and a new solution to install a purpose made foundation at
basement level was piled into the ground using mini piles. The tank was installed through
an existing floor opening, made slimmer and taller to achieve the required capacity.

2) Steam System Design

I was requested to quote for a steam system to supply a Devroniser on the Tissue Machine.
Proctor & Gamble (The Client) provided the system design from head office.
On inspection of the design I noticed that it was not fit for purpose and that fundamental
design flaws were evident in both the selection of components and overall layout.
I offered a solution to the client that I knew was of correct design and went through this
with their on site engineer in detail. I left the quote with them for perusal.

I was offered the contract to complete the works based on the fact that I was the only
supplier to query their design, even though our price to complete the works correctly was
more expensive than our competition.

The next issue was that they did not want to pay for a steam stress analysis so I
proceeded to calculate the system design myself from first principles. The system was duly
installed and commissioned. After completion P&G decided that they did now want to run
my design through a computer model, following pressure from their safety team and pay
for the previously refused steam stress analysis. I am proud to say that my design fitted
the engineering code well within requirements.

4. In what non-technical areas have you acquired an enhanced level of knowledge

and understanding (eg. finance, project management, commercial)? Please SPONSORS
provide example(s) of responsibilities which require you to have this level of INITIALS
knowledge and understanding to perform effectively.

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 I have in particular a high level of competence in project management of major projects
that include the need for design, technical knowledge and multi-discipline understanding.

Examples of projects that I have managed are as follows:

Year 1999 Upgrade of fine print and writing paper manufacturing machine (East
Lancashire Paper Mill) Circa 3.5M

Year 2000 2002 Project Management of various engineering upgrades to Tissue

Machine (Proctor & Gamble Trafford Park). This also included the management of the client
for my consultancy employer.

Year 2006 Project Management of Circa 8M project to expand South Korean Operation
(Tullis Russell Coaters).

Year 2007 Project Management of Circa 2M project to improve the paper finishing
department (Tullis Russell Coaters)

Budget Control

As Engineering Manager I produce, obtain approval and manage the engineering budget for
the Middleton Plant. For this I need to have a sound understanding of the company
finances and where my department expenditure impacts on overall performance of the
business.
The emphasis is always to reduce the cost of engineering without compromising
functionality, life expectancy, health and safety and end of life use.

Environmental

In year 2009 I gained my Associate Certificate in Environmental Management therefore

becoming eligible to join IEMA. I have since taken on responsibilities for the environmental
aspects of my company including management of 14001 and EMS. This further improves
my overall ability to positively improve my plant.

My involvement here is to lead the company and provide training on improving our
environmental impact. I have recently been recognised for my outstanding achievements in
2010 by the Milliken World Director of Manufacturing. This recognition was in the form of
an email copied to the senior leadership.

My achievements have been to reduce land fill from 65% to 5% over a 12 month period by
sourcing recycling routes for our waste. I have also reduced the energy and water usage of
the company above my 5% target each year since starting with the business. This was
through engineering practices and controls whilst introducing greater associate discipline.

Health & Safety

I have taken numerous courses throughout my career on Health & Safety in areas such as:

1) Understanding risks associated with engineering works.

2) Writing of Risk Assessments and Method Statements.
3) Managing safety of others such as contractors.
4) Developing and implementing safety systems for engineers.

Health & Safety is the number 1 consideration when applying engineering knowledge and
or principles. I have personally been responsible for designing lock out tag out systems and
associated permit to work systems and practices into companies where I have been
employed at management level.
I currently run the COSHH team at my current employer that involves leading a team of
associates to design and implement our own system for managing chemicals on site.
CEng CLA v10 Feb 13 9
 I have personally developed the training package and am currently in the process of
training teams in COSHH & Spill response.

5. What training courses have you undertaken that you would consider as
providing knowledge and understanding at a level at or above a Bachelors
degree? SPONSORS
(This might include University MSc modules or short courses and specialist INITIALS
courses organised by your company or third parties. If none, please indicate not
applicable.)

Associate Certificate in Environmental Management June 2009

In 2009 the environmental specialist left the business to seek alternative employment,
therefore creating an internal vacancy. Since I am eager to build on my experiences not
just in engineering but in other business areas I volunteered to take on the role along side
my engineering responsibilities.
I immediately requested training since this was an area I had limited experience of, and
the training programme recommended was the IEMA Certificate of Environmental
Management. I sat through circa 80 hours of lectures at the EEF and finally sat my exam
and passed with credit.
Since taking on this role I have partly re-written the Environmental Management System,
included our off site warehouse with extension to certificate and passed through the last
two external audits with no issues.
I have trained internal staff on COSHH, assembled an emergency response team and
prepared the site for compliance with legislation.
Recycling has improved from 34% to 96% of all waste now going to beneficial application.

Beloit Walmsley Maintenance Training Programme

In my employment at East Lancashire Paper Mill I attended this nationally recognised

maintenance course. From the course I was able to go back into my workplace with greater
understanding of not only how to maintain paper mill equipment but also how equipment
actually operated, including setup conditions.
This course helped me develop my understanding of paper machines giving me a great
platform to start from in the major refurbishment projects that I managed in the following
years.

NVQ Technical Services February 2001

Whilst completing my HNC in Mechanical Engineering I also sat NVQ level 3 modules based
more on the practical side of manufacturing. I took this course throughout my 5 Year
Apprenticeship that I personally believe has given me a strong advantage to lead
engineering through not only my academic qualifications and further learning, but also a
practical know how and understanding.

Attended 3 Day European Coating Symposium (Switzerland) September 2003

CEng CLA v10 Feb 13 10

 A high level symposium led by professors and academics from the coating industry, sharing
new technologies and breakthrough in understanding.
The course covered subjects from coating methods to instabilities in coating flows
demonstrated by modelling exactly what happens to flow using advanced computer
software never previously available.
I took back to the workplace a huge learning that helped me to understand problems on
our own coating machines I never previously understood. This helped me to solve issues
not only from pure engineering but also an academics view.

City & Guilds Level 3 AutoCAD

I believe that I am in a small number of engineers that have the ability to complete
projects at every stage through initial concept, design, specification, technical drawing,
procurement, installation and overall project management.
To ensure that I am equipped with what I believe are the necessary skills to make me a
more rounded engineer, I studied & qualified in AutoCAD at City & Guilds Level 3.

Paper Making Technology Orientation (UMIST) January 1996

Further training to enhance my understanding of how paper is made and the technical
details required as an engineer working in this industry. I am a firm believer that to
perform at a high level in industry I must make every attempt to keep up with technology
and understand the machinery that I have to interact with not only at maintenance level
but also at improvement stage.

Thermodynamics (Fundamentals of Steam Systems) April 1999 - Johnson Corp

This course has proved useful so many times in my understanding of the fundamentals of
steam, its properties and how to control and use it in industry. All of the companies I have
worked for since my apprenticeship have used steam for drying, curing or simply space
heating.
Through courses such as this and self learning I have become proficient in design of steam
systems, problem solving and maintenance of such.
Whilst working as a consultant I have used my knowledge to design steam systems
manually without the use of software, taking into account steam stress analysis.

Various Health & Safety Courses

To enable me to manage the health & safety of not only myself but others that I have
responsibility for, I have attended numerous short courses during my career covering
everything from applicable rules and regulations, manual handling, LOLER, PUWER, air
monitoring, personal exposure limits, to site specific rules.

Safety related Risk Assessment and Management Courses

I have attended course on how to manage the safety of associates and external contractors
by assessing risks associated with their tasks and designing safe method of work.
I use my skills here on a daily basis to manage external contractors through site safety
inductions, toolbox talks and ensuring their safe systems of work are satisfactory.
I am also responsible for controlling and developing the safe systems of work for
engineering and environmental tasks.

Internal Quality & Environmental auditor qualified

I take interest in any courses I can take to help my company manage their systems and
improve working practices. I have been trained to carry out both environmental and quality
audits to ISO90001 & ISO14001 standards.
I am currently part of the internal audit team for Quality Systems. I cannot audit
Environmental since I am responsible for maintaining the EMS.

Attended Milliken Leadership Courses Year 2010

CEng CLA v10 Feb 13 11

 An extremely useful course on the aspects of leadership rather than management. Milliken
desire that all managers must be leaders and by this they determine that being On the
system rather than being In the system is a successful route for leadership.
The course was run over four days and involved a great deal of interactive team play based
on changing the way we operate as individuals on a daily basis.

From this course I have taken away a greater understanding that leadership brings greater
success to pure managing. It is a Milliken perception that Managers tend be spend too
much time working in the system with their teams rather than leading at a higher level.

Attended a serious of monthly courses on Management, Finance, Sales, Marketing

whilst working for Tullis Russell Coaters

This was an extremely important series of daily workshops run one day per month for a
several months covering all aspects of the business.
The course was run by Training 2000 by specialists from industry in each topic.
This was aimed at Managers to give a greater understanding of each facet of the
companies departmental responsibilities and purpose, how each department interacted and
how important the correct flow of information was.

Milliken Ongoing Training

Aside from my Engineering & Environmental responsibilities I am currently running a

project to improve process reliability on a particular manufacturing line that produces mats
with recycled rubber backing. The process is complicated and uses a chemical process to
bind the rubber crumb. The machine is equipped with automatic cutting ad camera
recognition system for fabric design. This will involve a great deal of analysis and use of Six
Sigma and LEAN Methodologies.

I am currently waiting to start a course on Six Sigma through the Milliken Green Belt
Accreditation scheme. This will undoubtedly give me tools to be able to analyse problems
at a higher level and manage projects such as that described above.
This course is due to start in the new year 2011

6. Please provide details of any other evidence that you feel is relevant but has SPONSORS
not been covered in your previous answers. INITIALS

Current (Milliken Industrials)

As Engineering Manager I regularly need to refer back to my underlying technical

knowledge to solve problems with plant, machinery and processes. My role is different now
and more managerial than in previous companies.

Over the past year I am also now a point of reference for other Milliken Engineering
Managers at other UK sites and offer advice when required.

Examples of applying my knowledge in my current role:

1)

Recently the engineering department needed to change and upgrade a complete air system
on an industrial computerised washing machine.
The engineers had worked long hours to bring this machine back into production but at the
last part during commissioning a couple of sequences were not functioning correctly.

CEng CLA v10 Feb 13 12

 It was difficult to ascertain what the problem was since the upgrade had involved the
replacement of a complex manifold with 15 two port electrically actuated pneumatic valves.
The engineering team leader called for my support. I listened to the problem from the
point of view of my engineer, and personally watched the machine performing the incorrect
functions. The situation was furthermore complicated by the fact that there were no
original drawings to refer to and only those provided by my engineering staff through this
recent rebuild.
Since there was originally no drawings, over the course of two hours I systematically had
to follow each air pipe and understand where they went and how each switch or piece of kit
they went to was meant to function.

It was with engineering understanding and application of experience that two valves were
noted to be incorrectly connected and the situation was resolved.

2)

In my employment within the paper coating industry, process issues often occurred that
required engineering support. This support could be to determine where contamination was
coming from during coating to developing system the mix new products and pump to the
machine system using sophisticated controls.

One project in particular was dust and small particulate contamination found in coated
surfaces coming from 2 coating lines. On analysis I discovered the source could be from old
building materials since the machine house was over 100 years old.
Engineering solutions were put in place to line the coating booths, followed by design and
installation of filtration systems in line to the air knife coating systems.

3)

A recent example of applying engineering knowledge is where a complex issue was arising
on the vulcanising press resulting in pinholes developing during the rubber curing process.
The issue appeared on an edge reinforcing strip that is applied to the product.

The company has a history of believing that previous pinhole issues were being created by
the release sheet present on the top of the rubber during the vulcanising process. We had
recently been through an issue with the release sheet manufacturer and changed to
another supplier.

Analysing the rubber after vulcanising I could faintly see a witness of contamination within
the pinholes. The first thought in my mind was that this looked like polythene from a non
stick liner used between each sheet of rubber. The rubber was given to the laboratory for
further analysis that proved this to be in fact polythene.

Following the process back through the system I came to the conclusion that this was
being pushed into the reinforcing strip during manufacture where holes we punctured into
the strip by a spiked roller system on the slitting machine. Replacement needles by the
engineering team resolved the issue.

SPONSORS DECLARATION OF EVIDENCE

The formal assessment of the underpinning level of academic knowledge which will determine the category
of registration possible will be undertaken by the Academic Assessment Committee. Sponsors should
indicate as to whether the information contained within this application provides a fair representation of the
applicants career and engineering understanding.
I know this candidate in my capacity as their:

Mentor Line Manager Other (please specify below):

I hold Chartered Engineer registration with the

following UK Professional Engineering Institution:

CEng CLA v10 Feb 13 13

Sponsors Name: Registration No.

Signed: Date:

CANDIDATES DECLARATION OF EVIDENCE

The evidence described in this document is a true record of the academic knowledge that has been
demonstrated by me, and the evidence is available for review, if necessary.

Signed: Date:

This form was checked by*: Date:

* It is not a requirement to have this form checked by a Chartered Engineer prior to submission but, if you have received such
feedback on a previous draft, please enclose the feedback details with this application.

YOUR FORM WILL BE REJECTED IF THE DECLARATIONS OF EVIDENCE ABOVE HAVE NOT BEEN
SIGNED BY YOU AND YOUR SPONSOR, OR IF YOUR SPONSOR HAS NOT INITIALLED EACH SECTION
OF THE FORM.

THERE IS A 30 CLA CHARGE PAYABLE ON APPLICATION

This is to cover the costs of administering this application. If you need to undertake Career
Learning Assessment before commencing the membership application process, you should include
a cheque for 30 with this form to cover the administration costs of this assessment. Once you
are ready to make a Membership application, you can apply online with a reduced membership
application fee of 80, which can be paid as part of your online submission. If applying using a
downloadable pdf, the application fee is 115.

Please return the completed form and payment to:

CLA Review Accreditation and Professional Development Department

Institution of Mechanical Engineers
1 Birdcage Walk
London SW1H 9JJ

CEng CLA v10 Feb 13 14