Mourad Senouci CEng

Experience

• 

  Republic (Retail) Ltd

  Jun 2007 - Dec 2011

  Sales Assistant

  Working as a customer sales assistant, I used my communication, social and ability to work under pressure to assist customers to make an informed decision on their purchase. My interpersonal skills helped me deal with a diverse range of customers.

• 

  Rolls-Royce

  Jun 2010 - Sept 2010

  Summer placement (thesis)

  I conducted research and testing to fulfil the objectives of my MSc thesis at the Rolls-Royce site in Inchinnan, UK. This placement gave me an insight into the aerospace industry and this is where I am working now.

• 

  Assystem

  Jan 2012 - May 2017

  • Worked on projects on behalf of Rolls-Royce to create new design solutions from concept stage to certification and service. Taking component solutions through the Design Review process. • Completed Design Failure Mode and Effect Analysis (DFMEA) on various components. This ensured that risks were identified, and measures were in place to counteract them. • Created tolerance stacks alongside GD&T to determine possible fouls with interfacing components. • Defined and coordinated a testing programme for laser drilling of cooled turbine blades. Resulted in the reduction of non-conformance of air flow. Presented to Chief Engineer. • Led discussions with manufacturers and Stress/Coating departments to ensure a comprehensive validation strategy is implemented. This included the leading of risk reviews and ensuring all risks were mitigated. High risk topics were escalated to Chief Engineer with a mitigation strategy. • Defined new internal cooling passages on turbine blade, providing a number of design iterations to Stress team. The weight and life of the shank and firtree were considered throughout the process. Show less

  • Chartered Design Engineer

    Aug 2013 - May 2017

  • Graduate Non-Conformance Engineer

    Jan 2012 - Aug 2013
• 

  Wyman Gordon

  May 2017 - now

  • Leading the engineering department for our Livingston plant, providing coverage for our Lincoln plant when needed. Working closely with the European H&S manager to ensure all processes adhere to guidelines governed by the HSE. I have completed IOSH managing safely training.• Driving safety, quality, cost and process improvements throughout our components within our current order book. Spearheading NPI projects, ensuring all stakeholders actively participate in discussions as well as complete actions relating to sales, material supply, logistics, quality, as well as export control.• Responsible for productivity improvements in the machine shop including eight CNC machine tools. Driving development and time/cost saving initiatives, Introduced new carbide inserts, specially made tools for challenging machining operations as well as the optimisation of CNC programs using Vericut Force. I have a strong relationship with our sister machine shop in Pilsen, Czech Republic. • Manage the repair of dies on site as well as for our Lincoln plant by coordinating with the forge planner in the first instance but also closely with the weld and machine shop teams• My department is responsible for the dispositioning of non-conformance reports (NCRs) on manufactured components across all three Wyman-Gordon European plants. Whilst investigating and recording occurrences, my team and I will work towards determining root causes with an aim to reduce NCRs across these plants.• Making trouble shooting decisions across multiple manufacturing departments often under tense conditions and small-time windows. • Able to achieve and deliver the above with the support of my highly skilled and adaptable team of engineers. I can understand technical tasks and link them with business priorities which allows me to deploy the most effective resource I can. Coupled with my soft skills, I am able to do this whilst maintaining a strong team dynamic. Show less • Supporting the Engineering Manager, taking a lead role when required and deputising in manager’s absence.• Led the procurement of tooling (up to $1 million packages) and maintaining relationships with multiple suppliers ensuring lead times and costs are aligned with forge schedules and budgets. • Conducted on-site audits of European tooling suppliers, ensuring manufacturing capability as well as contract review processes, quality control and traceability are of an adequate standard. • Assisted with the identification, development and implementation of process improvements.• Performed contract reviews, considering customer specifications, tooling availability and forge schedule capacity.• Led the development of forge simulation and optimisation software within the Engineering department. Working with colleagues in our plants in Houston and Grafton, US.• Assembled working manuals (SOP, WI, TIG) to allow forging operations to be carried out safety and effectively. Whilst providing the company with documentation which provided adherence to HSE guidelines. Show less • Responsible for the development of production routes for forged products in Titanium, Nickel and Steel based alloys. These products are used in the Aerospace and Oil & Gas industries. • Created product and tooling drawings whilst following drawing control standards for customers as well as Wyman-Gordon. • Prepared forging simulation reports for customers with in-depth analysis of strain, temperature and forging practicality. • Point of contact for on-going shop floor operations including die inspection and repair as well as the forging of all products. Ability to make decisions in time constrained situations. • Created cut-up drawings that meet customer specifications whilst also ensuring that specimen blanks are taken from critical areas within each component. • Investigated findings of low strength properties in forgings and designed a new cooling process that has proven to improve cooling rates post forging. Read across to products in DA 718 group. Show less

  • Engineering Manager

    Apr 2023 - now

  • Senior Production Design Engineer

    Jan 2020 - Apr 2023

  • Production Design Engineer

    May 2017 - Jan 2020