Jonathan Bousfield

CAD Upgrade Feasibility Study

CAD Upgrade Study, Assessing Hydestor operational needs and recommending next steps to bring their CAD data and Data management up to industry best practice, in order to realise operational and production efficiency improvements.

Production Data & BOM Automation

Assist with production data and Bill of Material Management to automatically order and output hundreds of sorted product specifications for data entry, creating huge operational efficiency improvements.

Automated Conveyor Design Systems

Utilising highly automated inventor models and Macros to rapidly create standardised conveyors, also making custom modular conveyors for specific process areas.

Heavy Equipment Design & Analysis

Developed mechanical and structural designs for heavy process equipment. Employed SolidWorks PDM for file management and conducted FEA analysis to optimize strength, capacity, and material cost.

Project Coordination & Oversight

Coordinated project activities with staff, contractors, and stakeholders. Managed project timelines and budgets, offering engineering support and oversight.

Bioengineering Prototype Development

Conducted product research and development in the bioengineering field. Designed and tested prototypes using Fusion 360, evaluating and selecting viable options.

Vapour Scrubber System Development

Working on a tight timeline, developing and detailing process equipment and piping for a vapour scrubber system.

VBA Automation For Drafting Upgrade

Built VBA macros to automate a rapid upgrade from a previous drafting standard to another, as well as automatically update mart and material properties.

Project Engineering

Managing a team of contractors on a brownfield site came with significant challenges, including day-to-day coordination with installation teams and a group of three consulting engineers responsible for drafting and design. Their role involved cross-checking designs against site conditions and integrating point cloud data to bring plans in line with reality. Additionally, I bridged communication with the internal, remotely-based mechanical team to address mechanical detail issues. Strong coordination, effective client communications, and problem-solving were essential to managing the unpredictable site and ensuring the project stayed on track. 

Materials Handling Installation & Refurbishment

Served as a central member of the project team on a major materials handling installation and refurbishment. Managed BIM coordination in a high security setting, aligning project activities among clients, contractors, and stakeholders. Supervised the mechanical team to meet daily and weekly delivery targets and provided project engineering support and oversight.

Project Engineering

Managed fabricators and suppliers for the conveyors, working closely with the installation team by regularly coordinating with the manager and leading hand. I also collaborated with the lead supplier to address product performance and oversee the commissioning of the conveyor system. I developed an integration plan and a detailed integration specification to hold suppliers accountable. The project involved extensive materials handling, requiring careful coordination to ensure successful delivery and performance.

Plant Upgrade Layout & Design

Measured existing factory layout on site. Modeled proposed plant upgrades in SolidWorks, and designed modifications to accommodate planned improvements.

Project Coordination & Engineering Support

Coordinated project activities among senior staff, contractors, and stakeholders. Managed project timelines and budgets, providing engineering support and oversight.

New Production Line

Fast paced project lead role, delivering remote design support for a new production line in Melbourne, leveraging the scalibility of the Caliber team to deliver a great deal of design and project support in a very short design window.

Meat Handling System & Retrofits

Managed a small project team as part of a larger program. Led project planning, task allocation, and resource planning under compressed timelines. Arranged retrofits and design upgrades for existing equipment, engineered a meathandling system using Intralox belt and overhead chain conveyors, performed engineering calculations in MathCAD, and coordinated work remotely under challenging site conditions while handling concurrent projects.

Macro Automation & Drawing Updates

Revised previous project designs into updated versions under tight deadlines. Developed macro automation within SolidWorks to efficiently update hundreds of models and drawings. Delivered precise mechanical drawings and generated accurate, comprehensive Bills of Material.

Robotic Processing & Conveyor Design

Assist with updating models for next generation of robotic processing, modular belt design, calculation and design of custom lift up conveyors.

Blast Freezer & Conveyor Systems

Designed blast freezer and conveyor systems, performed finite element analysis on critical parts and assemblies, and conducted analytical shaft analysis validated empirically using MathCAD. Employed drafting macros to manage large volumes of parts and drawings efficiently.

Conveyor Design & Fabrication Drawings

Modelled and produced fabrication drawings for finger conveyors and thin band type belt systems.

Food Processing Equipment Redesign

Modified and resized machinery used for muesli and chocolate bars, including layering rollers, guillotines, belt washers, and sprinklers. Designed hygienic stainlesssteel sheetmetal components for washdown environments. Worked with suppliers to select motors and belts, prepared engineering drawings, and collaborated with workshop teams to integrate learnings into current and future designs.

New Product Prototyping & Design

Collaborated within a small, multidisciplinary team to prototype a new product. Translated industrial design concepts into functional models, managed PDM via Windchill, and worked within a customerdriven framework for design selection. Considered safety, branding, and massproduction tooling in 3D modeling using Creo, and supported rapid prototype manufacture via laser cutting and 3D printing.

Offal Tower

This was a week-long feasibility study aimed at providing feedback to the client on their project brief. It involved defining their problem, exploring options for the first stage of work, and creating a detailed timeline for the initial two phases. This framework was crucial for generating a cost estimate to proceed. The next phase was picked up by another Caliber project engineer and the project was delivered successfully.

Food Production Equipment

Project lead to bring together a team to design and build revolutionary food production equipment at Tasti foods, from timelining to managing risks to budgeting to ensure project success.

Hot Water Heat Pump

Completed a detailed costing and feasibility study for this $1M project, securing stakeholder approval, selecting contractors, obtaining quotes, and defining project requirements and timelines. Established stage gates and a budgeting framework to improve risk and cost management throughout the project.

Project X

Managed this project end-to-end, working closely with the workshop coordinator and inventor to design, prototype, and build production equipment. A strong relationship with the workshop manager relationship ensured effective control of key areas and smooth project execution. The project was extended to create a second machine, incorporating lessons from the first phase. Starting with a project brief, the process involved design, procurement, two rounds of improvements, and risk management, ultimately delivering the project on time for production.

Prototype Production Line Support

Provided project and engineering support for a prototype high volume production line. Handled project administration, tool preparation, and motor and transmission system design. Modeled components in 3D using SolidWorks.

Bread Handling Conveyor Systems

Designing upgrades and new product handling mechanisms. This involved site measurement, specification, layout, and machine concepting.

Modular Breadpan Conveyor System

Measured existing factory layout for context. Designed a modular breadpan conveyor system featuring chain, belt mechanisms, switches, turners, and drawbridge access. Created 2D plant layouts in AutoCAD LT and converted 3D concepts into parametric SolidWorks models. Designed new mechanisms including productturning conveyors, vertical switches, and a drawbridge access system.

Bread Conveyor System Design

Engineered a bread conveyor system using Intralox belt technology. Coordinated design tasks among peers, incorporated machine guarding, and used SolidWorks configuration settings for rapid parametric design.

Responsible for the electrical, thermal, and mechanical design of a solar thermal system, including AutoCAD drafting of electrical and pipe schematics. Using Trimble SketchUp, I conducted 3D modeling and shading analysis, and employed tools like Excel, T-Sol, PVSYS, and HOMER for solar simulation and design. I managed the overall design, construction, and commissioning phases of the project.

Solar Thermal Power System

Design and installation of Solar City’s largest residential solar heating installation, a huge 30kW solar thermal array consisting of 94 solar water heaters, capable of reaching temperatures of up to 100°C.  All of the pipe runs had to be hydraulically balanced, thermally efficient, and allow for considerable thermal expansion.