Summer Placement: Department of Chemical and Biological Engineering, University of Sheffield

Aisha Khan, SELA Cohort 2015 

Did you know that less than 1 per cent of paper coffee cups in the UK are recycled? That paper coffee cups aren’t meant to be put into general recycling bins? That they are considered waste paper stream contaminants?

I had the opportunity of carrying out a placement through the SELA research bursary programme in the department of Chemical and Biological Engineering, University of Sheffield, working with Professor Peter Styring on the recycling of paper coffee cups.  

Summer Placement: Geotechnical Engineering in The Department of Civil and Structural Engineering, University of Sheffield

Sebastià Despuig Reid, SELA Cohort 2015

In 2008 the Government signed the Climate Change Act which has the duty to cut 80% of greenhouse emissions by 2050. Therefore, the government needs to shift to alternative and cleaner sources to produce electric energy like wind. Three quarters of the planet is covered in water; therefore, it is no surprise that we look further away from our coast shore to take advantage of powerful nature sources. Nevertheless, there are some limitations due to costs and current installation methods which are mostly related to the foundations of the wind turbine, therefore there is need to find solutions to manufacture and install larger and cheaper wind turbines to meet the Climate Change Act target.

Throughout the summer I undertook a research placement in the Civil and Structural Engineering department within the Geotechnical Engineering branch. My project was based on the study of offshore wind turbine rough foundations. I was able to propose my title, always taking into account the interests and suggestions of my supervisor. The project lasted 10 weeks overall and it was supervised by Paul Shepley, a lecturer in Geotechnical Engineering at the University.

The main objective was to analyse the behaviour of different rough foundations compared to the same smooth foundations that are currently in use. The tests were performed on scaled samples at the geotechnical engineering lab by applying a horizontal load at the head of the pile. Unfortunately, I didn’t have time to test all foundations and throughout the project I decided to narrow down my topic to tackle any gaps in the design codes based on the roughness of foundations. As I started accumulating a larger work load I decided to push my research project into my final year dissertation, where I will be able to tackle issue in greater depth.

This summer research placement gave me the opportunity to experience all the sides of being involved in research, which helped me decide if I want to continue my studies with a PhD after I graduate. Firstly, I had to develop a research proposal and a time plan to work out what I was going to do each week. I conducted a thorough search on what other researchers had found out about topic and wrote a literature review. I also had to find out what instrumentation I needed to perform the tests and learn how to use it. Finally, I wrote about the findings on the tests performed and how these fit with what is already in place.

This project was an incredible opportunity to learn about the subject, experience from first-hand the life of a researcher and work together with other academics which have a broad understanding of Geotechnical Engineering.

Summer Placement: Integrated Manufacturing Group at the Advanced Manufacturing Research Centre

Ben Quickfall, SELA Cohort 2015

Between my second and third year of university study I was delighted to be offered a 12 week summer internship at the Advanced Manufacturing Research Centre’s (AMRC) Integrated Manufacturing Group (IMG).

The AMRC are one of seven High Value Manufacturing, Catapult companies. The aim of these companies is to bridge between academic research and industry, completing research which tackles current problems and is industrially commercial. This is with the aim of maintaining Great Britain’s position as one of the world’s leading countries in state of the art technology and innovation as well as driving the country’s economic growth in this sector.

The IMG is one of the many divisions of the AMRC and has recently relocated to the newly built Factory 2050, which is the first reconfigurable type factory of its kind. The IMG focus on cutting edge manufacturing and assembly technologies, advanced robotics, flexible automation, next generation man-machine interfaces and new programming and training tools.

During the 12 weeks of my placement I completed a project with a colleague to create a Reconfigurable Factory Demonstration. This demonstration was designed to show a scaled down version of the capability and potential that an operational reconfigurable factory could have. This is the same concept on which Factory 2050 was built (and more generally Industry 4.0 has). The demonstration comprised of a focused Internet of Things (IoT) network, created solely for the equipment within the demonstration. The equipment included: ABB and KUKA robotic arms, a KUKA youBot which is an omnidirectional AGV, a Raspberry Pi 3 as the central broker for the IoT network as well as Arduino Leonardos connected to each of the larger pieces of equipment. The Arduinos connected to the robotic arms and the KUKA youBot itself communicated with the Raspberry Pi Broker via a MQTT messaging protocol.

Whilst I completed work with all aspects of the project, ranging from creating the electronic boards used to connect the Arduinos to the Robotic Arms, to programming the Arduino’s to communicate over the MQTT network in C++, my work largely focused on the automation of the KUKA youBot. It was my responsibility to program the KUKA youBot within ROS (Robot Operating System). ROS is an open source framework which is being increasingly used within multi device projects and more specifically projects involving robotics – as the name would suggest. The framework operates using a nodal network where messages are published to topics and received by nodes subscribing to the same topics, with the idea that each node could be programmed for each of the devices in the ROS network.

As well as being exposed to a vast amount of equipment and learning a lot of new technical knowledge, many of the skills I have been developing through SELA have been heightened further as a result of the internship. Working closely with just one colleague on the project improved my project management and one-to-one communication skills and highlighted the importance of producing clear and concise documentation/programming comments to enable a team to work efficiently.

Being fortunate enough to have had this experience at AMRC, with the avuncular nature of the staff and the company itself, implores me to recommend completing summer internships to any student. My time at AMRC was extremely beneficial to my technical and personal development along with also being thoroughly enjoyable throughout!

Summer Placement: Gripple

Sam Barnes, SELA Cohort 2015

As a mechanical engineering student, I looked for a placement that offered both the opportunity to put into practice the skills and knowledge that I had gained so far in my degree, and also to gain a broader understanding of engineering in a business environment. Following a very successful visit to their premises with SELA, I applied for a summer placement at Gripple Ltd, a Sheffield based engineering company specialising in wire tensioning devices and overhead suspension systems. Having applied through the People and Culture department I was invited for an interview with Neil Clarke and Charlotte Hill, both of whom were product managers in the marketing department, and was lucky enough to be offered a placement.

I had a range of responsibilities for the 10 weeks I was with Gripple, some within the remit of the marketing department and some out of it, but the main deliverable for my time there was a certification audit. Gripple manufactures well over 200 different products and kits, and each of these require approval and testing certification for different markets and customers - my task was to produce a definitive record of everything currently held by Gripple and then to identify any gaps in the certification that needed to be filled. The resulting directory enabled Gripple staff to quickly answer customer requests for certification and also ensured that further testing was not carried out where certification already existed, something that had been an issue at Gripple.

Outside of the marketing department I was also involved in product development work. The assigned project was to design and develop a product to secure commonly used cable basket for overhead electrical cables to an existing Gripple bracket range. This has two advantages, firstly it saves on hardware, reducing time and money for end users, but more importantly it is far safer in the case of a fire as traditional fixing methods are prone to failing in high temperatures, allowing the cables to fall. Commercially, this takes an established Gripple product and opens up another market and application that is not currently serviced, thereby adding incremental sales. The development involved a lot of work with 3D printers as these allowed me to test each iteration of the prototypes in a matter of hours, rather than days. This aspect of the placement was particularly valuable to me as it brought to reality all the principles and processes I’ve been taught in the first 2 years of my degree and directly influenced the direction of the product, although the project is still ongoing. The project also acted as a catalyst for me to learn from the experience of the other engineers around me. Whenever I encountered an issue or needed a second opinion the people around me were more than happy to help, which helped me to learn as well as helping with the progression of the project.

Looking back at my time with Gripple I see it as a great success - I was able to achieve everything I wanted from the placement, gaining experience and broadening my horizons. Having also discussed some ongoing work with the product managers, alongside my university work, I look forward to what the future holds for the company and me.

Summer Placement: Department of Chemical and Biological Engineering, University of Sheffield

Samuel Grant, SELA Cohort 2015

Over the summer of 2016 I had the opportunity to take part in the SELA Summer Placement Scheme. Through the programme I worked with Dr Mark Ogden in the Chemical and Biological Engineering (CBE) department.

My placement started off like any new research project, by creating a white paper of previous research in this area. This took about two weeks to finish, under the guidance of Dr Ogden, by which time I had gained some insight into the process that was being used and any limitations that existed.

I then began designing the rig, using CAD in order to create a dimensionally accurate design which could be used for ordering of parts and materials. In addition to this, I began sourcing additional resources that I would need to get the rig to an operational state. With the help of Keith Penny, Dr Ogden’s technician, I found a working Peristaltic Pump and the necessary tubing that would move the chemicals through the extractor. I must give my thanks to Keith, who without this project wouldn’t have moved as smoothly. One of the most important lessons I have learnt during this project is that the vital role technicians play in research is understated and that they deserve respect for the hard work they do, both in helping academics with research and the running of labs for undergraduate study.

With the design complete and materials bought, Keith and I began building the rig. The structure of the rig was going to be made of box section steel and would support rectangular sections of 13-ply plywood, which had been treated to be resistant to chemical spills.

Using an angle grinder, I cut the box steel to the necessary lengths that had been designated in the CAD design. After this had been done, I used a MIG (Metal Inert Gas) welder to join the sections together. This was an interesting experience, as I had never used a MIG welder before and the learning curve was harsh with the inclusion of a small piece of melted metal falling into my ear - an accident that even the most stringent health and safety supervisor couldn’t have foreseen.  However after two days of work with no more accidents, the rig was built. The extractor was placed within it and connected up to the Peristaltic pump. Testing was then carried out to check the rig had no leaks, and any leaks that were found were patched up using Teflon. In addition to this any electrical equipment that was used needed to be PAT tested, teaching me that it is important to schedule work orders in advance to avoid delays.

This summer was an insight into the life of an academic researcher, which is a varied and often challenging role within the university system. Hours of work can often vary from anywhere between a few meetings a day, through to twelve hours of designing and drawing using CAD. The challenges of working within a relatively small budget was also interesting, resulting in a hunt throughout the department for equipment no longer in use that could be requisitioned for use within my research , echoing the adage that one man’s rubbish is another man’s treasure. To any person going into research, I would recommend asking around your department before buying any expensive equipment, it may save you a significant amount of money.

I would recommend doing a research placement to any member of the engineering faculty as it is a rewarding experience that will definitely improve your career prospects.

Summer Placement: Cummins Turbo Technologies

Katie Atkins, SELA Cohort 2015

Over this summer I have had the opportunity to work as a placement student for 12 weeks at Cummins Turbo Technologies in Huddersfield. As a materials engineering student I felt a little out of my depth to begin with as we don’t cover the automotive and mechanical side of this industry at university, however I was lucky enough to be working within the materials department where I felt more at home. The team I worked with over the course of my summer was a group of very talented engineers and technicians who provided me with a variety of projects and tasks to work on.

I was trained in many different lab techniques, allowing me to carry out a great deal of tasks independently. My lab training covered many techniques including the use of cutting machines, interferometer and SEM. During my placement I ran 300+ samples on the interferometer assessing surface topography and practiced dye-penetrant methods on 100+ turbine wheels. In this industry there is a need for non-destructive testing as it accommodates the analysis of components during test cycles and without taking them apart - I learnt a great deal about the benefits of these methods and the ease of carrying them out.

I have been able to apply the theoretical knowledge I have learnt at university to real life problems and situations at CTT, including the identification of component failure modes, which was covered during my second year at university, but gave me the opportunity to practice. This really highlighted to me the benefit of applying theory to industrial problems in order to cement understanding and now have a much greater appreciation of failure and fatigue at an industrial level.

I have been able to employ and practice a number of skills developed through SELA whilst on my placement, including team work, project management and communication skills. By working in a large global company I have had to efficiently communicate with many senior engineers across different departments, and sometimes across the world, regarding results, project updates and deadlines. Over the course of my placement I have worked on 17 different projects, often simultaneously, and therefore time management has been very important in order to complete everything to deadline as my work has often contributed towards much larger projects within the company.

There are many experiences I have had at CTT that I would not have been able to get elsewhere at my age and stage as a student and will stay with me throughout the rest of my working life. I would recommend a placement at CTT to anyone studying engineering due to the brilliant opportunities and experiences, but also for the attention to detail and exceptional organisation of their placement scheme.

Summer Placement: DEWAG

Deven Darshane, SELA Cohort 2015

My internship this summer was at DEWAG from 27th June to 8th August. DEWAG are an electronics company that specialise in microprocessors designed and installed to suit a variety of needs, offering consultation as well as installation. It was particularly interesting for me to see how everything is done in-house, from the research and design to manufacture, assembly, testing and dispatch. My role changed frequently within my placement in order to see what kind of areas suited me. Coming from a mechanical background, I often found myself researching and learning more about process analysis, instrument technology and automation within the electronic field. Fortunately, a lot of these areas are included in my modules for my study abroad next year so hopefully I have a head-start from my classmates! Whilst I agreed with the company that I cannot write about the specific work I undertook, I can reflect on the both the skills I have developed throughout my placement, and how this has affected my future ambitions.

In terms of technical experience, my most enjoyable experience was building on my limited programming knowledge within a supportive environment, helping me to learn new languages and utilise different industrial software. It was very satisfying to get to grips with an area I have little knowledge in. Whilst a career in the electronics industry may not be something I want to pursue further, I believe the knowledge and skills I’ve learnt can translate to my degree and career afterwards. An area I’ve also developed is my communication skills, in terms of progress updates and deadlines between various departments of the company. When working on a project it’s vital to know where everyone is and what problems they’re facing on a daily schedule. Even as a new intern, I felt I could ask senior members for help due to the supportive culture. I found this very important as it grew my confidence and encouraged me to take more responsibility for the projects and tasks I worked on, leading to better quality work. The actual electronic industry is not something I want to pursue further, but I think it’s an equally important experience because it ruled out something I was previously considering, and thus helped me better identify what sort of placement I want for next summer.

Summer Placement: BuroHappold

Rhona Kerr, SELA Cohort 2015

Over the course of my 8-week placement I have been working at BuroHappold in their Leeds office. BuroHappold is an international engineering consultancy specialising in designing urban environments, transit hubs, city districts and entire cities. The company is known for creating innovative solutions to some of the globe’s most iconic infrastructure. Think; the Millennium Dome, the Olympic Stadium and of course Sheffield’s own Winter Gardens.

I have been working within the structures department and the project I have been working on is called Angel Gardens, which is part of the NOMA redevelopment project based in Manchester. Once complete, the building will be the third tallest structure in Manchester city centre, altering the skyline of the city. It will be situated next to One Angel Square, the award winning CO-OP headquarters, which was a project previously undertaken by BuroHappold and awarded BREEAM Outstanding status, as well as multiple awards.

Throughout my placement I have gained invaluable experience, learning how to design tall buildings. This was a rare opportunity, as tall buildings are infrequently built within the UK.

I learnt to use a lot of new software in order to do the analysis of both the ground floor slab and the shear walls within the tower core. My main duties have been looking at the reinforcement within both the ground level slab and within the core of the tower. This has meant analysing the deflection, the stresses and the cracking within the concrete to check it is within tolerance. I have also been responsible for designing the required reinforcement within the slab, doing punching shear calculations, as well as hand calculations to check the forces and moments within the single spanning slabs and the beams on the ground floor.

Working on one project has allowed me to gain an in-depth understanding of how all the components of a project fit together. I have witnessed how the structures team interacts with other departments, such as Geotechnical engineers to bring the project together. Although I have been working on only one project throughout my time in the office, I have had the chance to hear about the diverse range of projects Burohappold undertakes.

The extra activities provided is one of the reasons I have enjoyed working at BuroHappold so much this summer. I have been allowed to attend CPDs and structures club that have given me useful experience allowing me to constantly gain more knowledge about the industry. One particular event, which sticks in my mind, was a lunchtime structures club. The topic of the day- How close can you pile next to an existing building? The answer obviously includes many different factors: ground conditions, existing foundations, size of equipment etc. After a detailed discussion with everyone from the team inputting his or her previous experience and knowledge it was decided that for this case the answer was 1.5 metres.

Events like this created a sociable working environment which was perfect for a placement student with many questions! I am very thankful that completing a placement is part of the SELA scheme as I believe the experience will come in useful for the remainder of my degree course.

The UK Energy Trilemma

Elizabeth Rush, SELA Cohort 2014

On the 25th April, concluding an unbelievably prosperous two years as members of the 2014 cohort, the collection of 11 students set up for their final presentation on The UK Energy Trilemma.

The year long project began in October following the triumph of their previous project, the 2015 Bootcamp. Starting slowly the cohort were taught skills on infographics and causal loops that would ultimately be the conclusive dissemination of the project. Once the basic understanding of presentation was completed, then came the information. Over the year expert upon expert have lectured to the cohort with the likes of specialists in renewable energy, representatives from Siemens and ex-Members of Parliament talking about what technology is at the forefront of this wicked problem.

Working together with the insight given to us by these titans of industry gave us the tools we needed to tackle this project head on. We elected to divide sections of the work into energy sources and distribution , in turn giving these to pairs of members to critically analyse using all the assets we were fortuitously allowed. Breaking down powerpoints, recordings and handwritten notes into key points was an achievement in itself, but the information we gathered then had to be collated into a format that was simple and direct whilst maintaining the expert undertone that we were provided.

By the end of this process, members of the cohort talked confidently about how these elements affected the UK population and at this stage we were positive we were ready to present our findings. Enlisting the help of Robert (illustrator) he was able to transform the chaotic biro causal loops we handed over into intricately illustrated guides through the stressed problems and positives of the corresponding topic. These were made all the more dynamic after printing in full A0 which allowed the cohort to view the magnitude of what we had accomplished.

These posters were hung within the Diamond in preparation for the arrival of the SELA stakeholders, researchers and key speakers we had received over the course of the academic year.  As we quietly discussed the finishing touches to our presentations our guests began to trickle in, who we greeted with friendly faces and welcomed back enthusiastically. Following our opening presentations and brief overview of each topic, we asked our guests to examine our findings more closely and ask any questions they had for us. This section they were evidently prepared for as each member was in the line of their challenging questions, although our extensive research supported an entertaining debate for student and professional alike. The closing statements of the evening allowed us to thank our many guests for their attendance and to summarise what challenges we encountered and what we expect to come. Met by nodding heads and an emphatic applause the evening concluded, an event that we feel epitomised our success as members of the Sheffield Engineering Leadership Academy.

Get a Gripple

Katie Atkins, SELA Cohort 2015

On the 9 March, SELA’s 2014 and 2015 cohorts had the opportunity of attending a visit to the Loadhog and Gripple site in Sheffield – manufacturers of transit packaging and wire tensioners respectively. Both companies are part of GLIDE, an employee owned company that represents all its shareholders. The company is based on an innovative and creative business model not often seen in the world of engineering, and therefore provided a unique insight in a different style of management. Gordon Macrae, the Special Projects Manager at Loadhog and Gripple delivered a talk outlining their ethos and what to expect from the company.

A tour around the offices and factory floor allowed all the students to see the scope of the company and their unique design process in practice. Ideas boards, suspended art installations and interactive meeting spaces were all present and integrated into the office space. Although, for many of the students the expansive factory floor provided the greatest interest from a technical engineering perspective. Finally, following encouragement from Gordon many of us suggested methods of improvement throughout the design stages and factory processing, some of which were taken more seriously than others.

All members of SELA would like to thank those at Gripple and Loadhog that welcomed us and especially to Gordon Macrae for taking the time to speak with us.