I’ve worked on projects at various stages of maturity, which call for different approaches depending on product-level priorities. These stages blend between one another, are often iterative, and the projects I’ve been exposed to have defined their phase segmentations differently, but here’s a generalised overview:

Conceptualisation & Definition

Proof-of-concept Prototype

Early-stage Prototypes

Late-stage Prototypes

Start-of- / Post-production

Product Development Stages

- Searching for product market fit
- Primary and secondary research to scope end-customer needs
- Ultra-low fidelity prototyping to demonstrate design intent

- MVP: defined product category and value proposition(s)
- Gathering feedback from early adopters
- Quick iterations with rapid prototyping and off-the-shelf components

- Early low-volume testing (engineering validation tests)
- Soft-tooled parts
- Top-down analysis: requirements listing and system decomposition

- Detailed function and manufacturing de-risking (design and production validation tests)
- First-off hard-tooled parts
- Pre-production sample runs
- Bottom-up tests: verification and integration

- Change management for mid- / post-manufacturing updates
- Detailed optimisation for cost-down and reliability factors

Ocado Technology

2023 - Present

Ocado Technology ↗ develops fulfilment automation solutions for its online grocery business in the UK, as well as other clients globally, spanning multiple sectors. This includes the mechanical design of automated storage and retrieval systems (ASRS), which form the physical element of customer fulfilment centres.

Stage

End-to-end Product Development

0

1

ResponsibilitiesMechanical & Structural Design Engineering // Systems Engineering and Verification // Manufacturing and Production

As a mechanical design engineer, I was a member of a team responsible for delivering Ocado’s latest modular, lightweight and cost-optimised “grid”, the structural element of an ASRS which stores totes (inventory bins) within a cubic volume, and provides a track surface for robots running on top of the grid that deposit and retrieve totes.

By going through a full product development cycle, from conceptualisation and early prototyping, through to trial builds and first-time installation at a customer site, I was able to:

- Deliver total cost of ownership savings of 25% for a grid sub-system, throughout the components’ early life cycle: material, manufacturing and installation

- Resolve engineering issues by collaborating with teams responsible for: structural integrity and building code compliance, interfacing systems including robots and peripherals (decant/outbound and pickstation conveyor systems), site assembly and installation

- Initiate and conduct design of experiments and studies to gain confidence in the definition of system interfaces and quality targets, ultimately translating into functional robustness during operation