Senior Consulting Engineer

Roger Lewis is a qualified engineer and safety specialist with extensive experience in the application of engineering and human factors principles, product design, failure analysis and risk control.

Having over 25 years experience in automotive engineering and vehicle architecture, predominantly with Ford Australia and Ford Asia Pacific, with a strong focus on the safety of vehicle occupants and pedestrians, Roger brings a wealth of knowledge to his clients seeking to improve their safety and ergonomics environment.

Roger routinely advises businesses across a broad range of industries, including transport, logistics, manufacturing, construction and retail, on safe systems, ergonomics improvement, injury prevention, as well as compliance to relevant standards, practices, codes and legislative requirements.

Some examples of Roger’s work include:

• Enhanced driver cabin and seating arrangements for Z3 class trains (Downer Group)
• Safety and ergonomics assessment of new Myki equipment in several tram classes (Yarra Trams)
• Improved drivers seat headrest of B Class trams (Yarra Trams)
• Serious workplace injuries (e.g. amputations) involving plant, material handling vehicles (e.g. forklifts), guarding of machinery, and unsafe systems of work
• Product failure incidents involving bicycles, rollators and ladders
• Incidents arising from unsafe use of power tools including angle grinders and impact drills

Some cases Roger has provided Expert opinion in include:

• McDonald v National Express Group Australia – court evidence
• Metri v Nestlé Australia Ltd – court evidence
• Trtovac v Total Mix Pty Ltd and Anor – court evidence

Awards and Achievements:

• 2024: Registered Professional Engineer of Queensland – RPEQ
• 2023: Registered Professional Engineer of Victoria- RPEV
• 2023: National Engineer Register – NER
• 2012: Played integral role (vehicle engineering and architecture) in bringing the Ford Ranger to market
• 2001: Design for Six Sigma (Green Belt), Ford Asia Pacific
• 1998: Associate Diploma in Music Performance Australia (French Horn)

Memberships, Associations and Societies:

• An active member of Forensic Engineers Society of Australia (FESA)