John D. O'Callaghan

Experience

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  DePuy Synthes

  Jun 2014 - Aug 2014

  Manufacturing Engineer Co-op

  I worked in the Advanced Manufacturing Technology (AMT) department during this work placement. The projects I worked on were based on the development of two new production lines. I was involved with the validation aspects of these projects. I completed Requirement Traceability Matrices (RTM) and Design Qualification Protocols (DQP). I also carried out roughness tests as well as other day to day minor tasks. This work placement was extremely valuable as I gained great experience of the medical device industry after just completing the first year of my degree. Show less

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  DePuy Synthes

  Jun 2015 - Aug 2015

  Manufacturing Engineer Co-op

  I worked in the Foundry (Projects) department for my second summer work placement. My main project was the Single Tree Casting project. This involved casting one mould/batch of parts at a time. My duties were generating the required paper work for the trials and running test batches through the Foundry. I recorded relevant data from each of the process stages for each batch. I used this data to enhance the justification for moving to single mould pours. During this placement, I also worked on a wiring upgrade project for one of the Cleanrooms. I used my 3D modelling skills in this project to design and generate various layouts for the wiring. These drawings were shown to outside vendors in order to estimate the cost to complete the required work. The drawings were also effective to communicate the different aspects of the project with management. I thoroughly enjoyed this project due to its design aspect. Show less

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  DePuy Synthes

  Mar 2016 - Aug 2016

  Manufacturing Engineer Co-op

  My third year work placement was completed in the Foundry at both the DePuy Synthes Cork and Raynham MA sites. In Cork, I worked on Single Tree Casting and Tray cooling study projects. My duties included generating documentation, coordinating the trials, and recording unique aspects of the trials. I spent four months at DePuy Synthes, Raynham MA during this work placement. I was project manager of a Melting project. The aim of this project was to increase the melting power of the induction furnace used to melt the metal crucibles prior to casting/pouring product. The project involved verifying that the current induction furnace could operate at the required higher power. I also had to establish an adequate sample size for the trials i.e. including a range of product families and sizes. I managed the processing of the test batches through the Foundry. I coordinated completing the pours at the higher power with the Operation and Facility teams. I verified the induction furnace was returned to its correct settings prior releasing it back for production. For each pour, I recorded as much data as possible e.g. melting time, argon consumption etc. This data was used to enhance the justification for the project. All the trials were successfully completed. I also worked on the Single Tree Casting project for the Raynham site. I supervised each stage of the process for all the trials to ensure they were carried out correctly (certain steps were different to production process). I completed scrap analysis on the trials in order to increase justification for the project. I coordinated the building of the test batches with Operations. I designed a number of instruments/parts to aid the assembly of the test batches using Autodesk Inventor. The models were used to 3D print the parts on-site. I worked on the validation of a new laser machine. I generated and completed the IQ. I operated the laser for the FAT. I also generated an Operating Procedure for the new laser. Show less

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  DePuy Synthes

  Sept 2017 - now

  • Senior Materials Engineer

    Nov 2022 - now

  • Materials Engineer

    Sept 2017 - now