QUALIFICATIONS
- BE Mech (Hons) – 2014
- Diploma in Design & Specification of Plastics
SOFTWARE
Mechanical CAD Software
- Creo (PTC)
- Inventor (Autodesk)
- SolidWorks (Dassault)
PDM/PLM Software
- Inventor Vault (Autodesk)
- SolidWorks PDM (Dassault)
- Teamcentre PLM (Siemens)
- Windchill (PTC)
Analysis Tools
- Creo Simulate
- Inventor Nastran (Autodesk)
- SolidWorks Simulation (Dassault)
Alister Forsyth
MECHANICAL ENGINEER
Skills Overview
Alister is a Mechanical Engineer (BE Mech Hons) with 10 years of broad expertise in mechanical machine design, product design, project engineering and analysis; both in New Zealand and in the Netherlands. Known to be a capable communicator, solid problem-solver, with his “design for manufacture” mentality, he constructively bridges technical skills and soft skills. Alister operates confidently as an independent lead on complex, high-pressure projects and brings the same hands-on diligence to every situation regardless of industry or scale.
- MACHINE DESIGN & PRODUCTION AUTOMATION EQUIPMENT – Alister has experience in the design and analysis of a broad range of machinery, including marine waterjets, manufacturing automation equipment, conveyors, excavator tools for construction, gantries, post-harvest produce handling systems, and elevators.
- FAILURE MODE & EFFECTS ANALYSIS (FMEA) – FMEA methodology is embedded in Alister’s design approach. It informs how he prioritises time and resources, and provides a framework for product and machine acceptance. His FMEA approach has been refined through the delivery of many projects, including on-site work across manufacturing environments and facility installations.
- PROJECT ENGINEERING & DELIVERY – Alister has undertaken site measurements, CAD design, IFC drafting, and published documentation for a greenfield industrial refrigeration installation. He has also worked as the lead architect on an NPI oven project, and has coordinated local and international teams both in person and remotely.
- MECHANICAL ANALYSIS & STRUCTURAL DESIGN – Alister has experience in mechanical analysis using Inventor Nastran FEA, Creo Simulate, and SolidWorks Simulation. He methodically checks analysis against first-principles hand calculations. His experience includes calculating structural member stresses, FEA Von Mises stress, bolted connections, welded connections, and fatigue assessments across heavy industrial equipment and structures.
PERSONAL STATEMENT
I am born in the North Island of New Zealand but have found a new home in the South Island after moving down to Christchurch in 2011 to study Mechanical Engineering.
My background spans product development, certification and compliance, FEA analysis, automation, machine design and construction equipment, across New Zealand and Europe. Having worked in New Zealand for 8 years and the Netherlands for 2 years, in small, medium and large organisations, I bring a diverse skillset to the table.
What drives me: the satisfaction of problem solving my way through difficult challenges. Getting deep into building and evaluating, from concepts through to completed functioning designs.
Outside of work, I’m an outdoor enthusiast, that can be found riding mountain biking trails, snowboarding on and off-piste, hiking and camping amongst the alps. I also enjoy tinkering with car maintenance and lodge maintenance up at a community ski club.
Project Experience
FISHER & PAYKEL APPLIANCES
Oven Platform Upgrade
Worked collaboratively with a team in the development of an oven platform upgrade. My responsibilities included incorporating new structural changes to be cross compatible with older generation platforms, supporting an R&D fan development project, and providing extra resource for new technology integration into current oven platforms. These projects predominantly required the use of sheetmetal design, 3D printing design, product testing and detail design.
OMYA MINERALS
Bulk Materials Handling
I oversaw the CAD design, calculations and manufacturing drawings of a bulk materials hopper system. Tolerances were of key importance as many interacting parts were having to mount from different surfaces. Commissioning remotely required concise, clear correspondence to evaluate if the built condition met required fit and function for purpose.
SCOTT TECHNOLOGY
Automated Manufacturing Line
Developed detail design models and manufacturing drawings for a couple of stations in an automated manufacturing line. This involved quickly learning the technicalities of machine design, using special techniques to precisely locate product and tooling to tight tolerances, within a constrained space envelope. The design required the use of robust press tooling, hydraulics, pneumatics, lightweight aluminium structures, guide rods, bearings, and multiple degrees of freedom of the system.
AG RESEARCH
Enclosure & Holster
Designed a weatherproof and ergonomic plastic enclosure and holster to house electrical equipment and sensors. The device was designed utilising several different 3D printing features all within a constrained timeframe and budget remotely during lockdown. CASE STUDY
WYMA Solutions
Post-Harvest Handling Equipment
Design and manufacture of equipment for post-harvest handling of fruit and produce. Designed conveyors, structures and platforms utilising sheet metal and frame elements constructed using both bolted and welded constructions.
FISHER & PAYKEL APPLIANCES
Cooling System for OB60C Oven Platform
None of our existing cooling system solutions met the needs of the project, hence a new cooling system needed to be designed from scratch. My task was to innovate a new in-house manufactured centrifugal fan, develop CAD, create manufacturing drawings, derive tolerances, build and test prototypes, troubleshoot manufacturing, production and reliability difficulties and manage the project from start to finish with a team spanning across multiple countries.
GOOD BUGGER AWARD
September 2021
Alister delivered a project for a new customer, AgResearch, while in lockdown. The project was very time-constrained, and Alister did an excellent job communicating with the customer and helping manage project risks. In addition, he developed an FMEA template that is now the standard for all Caliber Engineers.