Johnny Zajac

• Inverter (motor controller), 400V, 150kW, Design and Test from Alpha through to production for Industrial Machinery market.
• Inverter (motor controller), 48V, 20kW, Beta design, V&V and release to production for Industrial Machinery market.

For the 400V design:

• Produced the Schematic and PCB design, and manufacturing drawings release in Altium. Organised and lead group design reviews and implemented changes.
• Fully organised and completed the product certification to UL-583, including guiding UL on-site for witness testing.
• Resolved significant EMC emissions issues through good-practice design and pre-compliance investigation. Managed to reduce emissions by 20dB to get compliance with REG-10, EN12895 and ISO13766.
• Testing including all regulatory per ISO16750. Environmental (Climatic, Vibration, IP), Chemical, Thermals, EMC, Electrical.

Generally:

• Design for Insulation Coordination (Creepage and Clearance) for multiple products, to EN60664, UL840 and EN61800-5.
• Experience with standards Industrial Machinery standards EN1175, EN13849, UL-583, ISO20898.
• Full V&V testing for multiple products.
• Managed the creation of new components into global parts system, including BOM scrubs, component analysis for viability, second-source, lifetime, qualification, etc.

• Designed and tested a range of HVAC variable speed drives 3-17kW, 180-633Vac
• Created our Hardware Design process to ensure consistently professional work products
• Responsible for integrating junior team members and managing their work

• Worked on seven projects, experiencing all stages of the product lifecycle from concept to serial production
• Developed industrial and automotive electronics, specifically VSDs (variable speed drives) and power supplies in the range of 3 - 200kW, 12-800VDC
• Designed a flagship VSD to ASIL-D (ISO26262), aimed at volume manufacture (100k/y); specified requirements and created schematic and PCB layout with Mentor Graphics.
• Delegated tasks to Technicians and Engineers whilst executing verification test cycles
• Directed validation test cycles for multiple products in our facility and at an external test house
• Presented multiple 8D investigations to our customer following my analysis and correction of design issues
• Managed communications with our suppliers for critical and custom components

• Plextek Consulting
• Worked at a radio electronics consultancy, developing antenna designs and image processing algorithms.

• Performed effectively as a team member and leader with the responsibility of daily operations and training/delegating new staff.