Portfolio

During 2023 and 2024, M.E. developed a commercial-grade, portable trough cart for use in the events, entertainment and catering sector. The product—which began as a napkin-sketch—was designed and manufactured according to the client's needs.

Frustrated by competitor's equipment, which was prone to breakage and lacking  professional appearance, our client required more durability, bespoke custom features, and a more refined appearance. 

• Design and Development:

  • Presented multiple design renderings based on customer input

  • Utilized industrial design principles focused on all-custom metal

  • Employed Fusion360 for:

    • Rendering design concepts

    • Part design and assembly

    • Structural simulation

    • Creating technical drawings for part production

• Manufacturing and Assembly:

  • Collaborated with suppliers to manufacture custom sheet-metal parts

  • Assembled and delivered the final product

  • Developed work instructions for manufacturing

  • Designed packaging

• Product Support and Documentation:

  • Provided ongoing support by supplying replacement parts, custom accessories, and performing repairs

  • Produced product datasheets and owner’s manuals, including assembly instructions

• Marketing and Sales:

  • Handled advertising and sales of the product

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In 2023, M.E. manufactured in-house a set of custom bars and a bar shelf, following photos which were provided by the customer. 

• Material Sourcing and Processing:

  • Sourced materials essential for construction

  • Employed cutting and welding processes for framework

• Finishing and Detailing:

  • Chrome plated the bar frames for a sleek finish

  • Utilized laser cutting for acrylic inserts based on our drafted drawings

In 2022, M.E. supported a developer and manufacturer of medical devices with development of a portable ozone generator medical device with mechanical design and prototyping services. Specifically, we: 

• Provided detailed cost estimate for our services. 

• Participated in design review meetings, providing input on manufacturability of initial 3D model.

• Expanded in-house fabrication capabilities to meet project needs. 

• Selected aluminum and steel alloys and dimensions to meet structural needs and minimize total product weight.

• Fabricated 120 aluminum sheetmetal parts to build three prototype units.

• Developed a set of local suppliers to provide small quantities of goods and services, including: 

  • Powdercoating

  • Alodine treatment

  • Waterjet cutting

  • Welding

  • Sheetmetal bending

• Contributed written design improvement feedback during design review meetings held after completion of each protoype. 

• Translated design improvement requests into sketches, then CAD drawings, and finally prototype assemblies.

• Documented part designs with hand sketches and CAD software, and prepared formal design packages.

In 2023, M.E. contributed to the implementation of a quality management software uniPoint within an ISO13485-accredited developer and manufacturer of medical devices by:

• Supporting development of validation protocols

• Methodically executing validation protocols for multiple modules, documenting results in controlled test reports

In 2022, M.E. supported a medical device developer and manufacturer in the change control process within an ISO13485 accredited quality management system by:

• Organizing meetings with key stakeholders to collect technical information necessary for documentation, and develop alignment around reasons for and scope of changes

• Compiling concise summary of and rationale for change sections within change request forms for electrical and mechanical product changes

• Evaluated specific changes against Health Canada significant change flowchart

• Circulating documentation for review and approval by internal and external parties via Adobe Sign 

• Proposing form and process improvements

Between March 2020 and October 2021, Zach Mazurek worked full-time with a team of engineers and contract manufacturer within an ISO13485 QMS environment to rapidly develop reliability and production capacity of a highly complex portable life support system product, MOVES SLC, in order to fulfill a surge in demand caused by the COVID-19 pandemic. This project received rampant public attention: read more here.

Specific contributions to this project by Zach Mazurek (representing experience and capabilities now offered by Mazurek Enterprises) include: 

• Consolidating equipment used in production for controlled transfer to contract manufacturer

• Purchasing and renting calibrated electrical test equipment including leakage current testers and regulated power supplies

• Developing new test procedures and test jigs independently and in collaboration with other team members

• Creating and maintaining an end-of-line quality test procedure, and personally testing hundreds of units before delivery to customer

• Reporting weekly to top management on failure trends in production testing 

• Determining and investigating root causes of quality issues and working alongside engineering personnel to develop solutions—including supply controls, new assembly, and test procedures

• Developing a job ad, conducting interviews, and training an assistant

From the period between 2019 and 2021, in which Zach Mazurek held a Test Engineering role at Thornhill Medical, some notable responsibilities and projects completed include: 

• Sourcing, operating, and contracting the calibration and repair of controlled equipment, including patient simulators such as the Fluke Prosim 8 and Ingmar Medical ASL5000 breathing simulator, and other electrical and mechanical test equipment—i.e. electronic loads, leakage testers, and digital multi-meters

• Preparing medical device test subjects for V&V activities, such as a mobile life support system composed of approximately 1700 parts and 5 major sub-assemblies, by repairing, modifying, and qualifying through full assembly/disassembly, sourcing parts, soldering, cutting viewing ports, installing in-line switches and valves, and executing production test procedures

• Maximizing reliability of ventilator calibration process by creating a procedure, wiring harness, and test setup for characterizing and pairing gas flow sensors prior to their installation

• Determining shelf life for consumable products such as breathing circuits, carbon dioxide scrubbers, and carbon air filters by creating and executing stability testing protocols, and writing formal controlled reports documenting results

• Supporting 4th edition IEC 60601-1-2 EMC pre-scan testing at an electrical testing lab—applying product operation knowledge and documenting findings. In particular, some of the tests supported were: 

  • Enclosure Port Immunity to RF Wireless Communications Equipment 

  • Electrostatic Discharge Immunity 

  • Immunity to Conducted Disturbances Induced by RF Fields

• Designing and building a small electromagnetic vibration table to support investigation of a ventilator product quality issue that appeared following product shipment

• Methodically disassembling and testing an anaesthesia delivery device which failed in service alongside a time of engineers to determine the root cause of failure; documenting and communicating all findings

• Updating and executing design verification and validation test protocols after hardware and software changes to all of the five major subsystem PWAs of a mobile life support system 

• Developing a test procedure for the service manual of a medical device designed to treat carbon monoxide poisoning to evaluate three critical system characteristics and determine need for service

• Delivering an improving production ventilator calibration procedure and custom test jig to improve calibration quality and process reliability within an accelerated timeline of only three weeks

In 2019, Zach contributed to the development of a set of service kit products for MOVES 300, a portable life support system. 

• Developed a new multi-test fixture concept in collaboration with engineering personnel

• Designed test fixture to minimize initial cost and maximize serviceability by minimizing number of custom parts and cables

• Sourced parts and materials required to build test fixtures

• Liaised with internal Engineers and Technicians to make the required custom parts and deliver the assembled test fixture within a strict timeline

• Contributed written instructions, photos, test files, and feedback on others' work during collaborative efforts to develop production test procedures

• Developed validation protocols for test fixture, and performed validation

In 2016, at a masking tape production plant, Zach designed parts for and managed the implementation of a solution to an issue causing production downtime and requiring frequent operator intervention. Rolls of masking tape expected to roll down an inclined table would frequently lodge against guide rails, requiring an operator to stop production and manually dislodge these. A solution already proven nearby was to install a vibrating motor on the underside of the inclined table. Specific tasks completed by Zach for this project include:

• Designing a safety gate latch system and inclined table using SOLIDWORKS software

• Updating electrical schematics to include new vibrating motor using AutoCAD

• Preparing and distributing mechanical drawing package to suppliers for quotations

• Contracting licensed electrician and mechanical services to install the new equipment

• Integrating vibrating motor into function block PLC programming using Schneider Unity Pro software

• Coordinating logistics and timing of installation with production scheduling personnel

• Monitoring to verify effectiveness of solution

In 2016, in a masking tape production plant, Zach completed a project intended to eliminate downtime caused by condensate backup from electrical cabinet air conditioning units damaging electronics. Steps taken include: 

• Printing and applying serialized high visibility labels to all AC units, to aid communication

• Cleaning and replacing air filters

• Contracting specialized service and repair of AC units

• Selecting and purchasing PVC plumbing materials and condensate collection buckets

• Designing and installing reliable hard plumbing condensate drains, marking locations for condensation collection buckets, and outfitting buckets with electrical cabinet IDs to discourage re-purposing

• Creating AC unit registry, including location descriptions, used for condensate bucket-emptying weekly routine

In 2008, Zach started his first small business with the support of the Ontario Summer Company program, and the Leeds and Grenville Small Business Enterprise Centre. 

• Wrote a business plan, received business grant

• Completed business training

• Performed repairs and rebuilds on all types and brands of machines, including: motorcycles, lawnmowers, snowblowers, chainsaws, trimmers. 

• Operated on a satisfaction guarantee standard

• Attended weekly meetings with local business mentors

An ongoing personal project which began in October 2008, Zach Mazurek is rebuilding his 1987 Chevrolet R10.

Major accomplishments of this project, testifying to Zach's versatility, include:  

• Cutting out rusted body metal including rocker panels, floors, sections of box sides, and welding in replacement panels which were purchased or fabricated

• Preparing frame and full underside of body for refinishing using sandblasting, grinding, and rust converter chemicals

• Replacing TH350 automatic transmission with a custom hydraulic clutch pedal system, and later model NV3500 manual overdrive transmission

• Rebuilding 350cu. in. Chevrolet small block engine with approximately 400hp

• Installing full OTS stainless steel brake line kit

• Forming and implementing custom fuel hard lines using 37 degree flared fittings and 3/8" OD, 0.028" wall thickness precision steel tubing

• Mixing, applying, and shaping body filler products

• Applying professional automotive primer and paint products using an HVLP spray system

• Designing, building, and installing custom subwoofer box and stereo