During my Product Development Internship at Ford, I had the opportunity to work extensively with Siemens Teamcenter and TcVis, tools that I had to quickly familiarize myself with to perform effectively. My main project revolved around creating a virtual vehicle and corresponding Bill of Materials (BOM) for the front-end module of a future product. This virtual model addressed engineering concerns about front-loading and component integration and was used as the basis for a physical model built by a contractor.
The task was particularly complex because the product had three variations, each with unique configurations. Differences included larger frunks, additional cooling lines, enhanced thermal management systems, and radar sensors. I started by selecting essential part groups for a frame-up build while excluding unrelated components such as wheels, suspension, and steering. After identifying the differences across the three models, I created a new object in Siemens Teamcenter and exported it to Excel.
In Excel, I developed macros and filters to streamline the contractor's ability to sort through data, such as part numbers and associated design engineers, and organized the components into a hierarchy to simplify navigation through the various modules. I also conducted Digital Pre-Assembly (DPA) checks using TcVis, ensuring that parts maintained adequate clearance to prevent NVH or reliability issues. For components that fell below minimum clearance requirements, I collaborated with engineers to confirm compliance with design intent.
Beyond this core project, I took the initiative to enhance my skills in my spare time by utilizing Ford’s training materials to learn CATIA V5, further expanding my CAD proficiency. Additionally, I participated in enrichment activities such as volunteering events, a transmission teardown, and contributing to the filing of a patent for a regenerative system for an electric vehicle.
During my internship at Navistar Inc., I played a key role in investigating returned Exhaust Gas Recirculation (EGR) valve parts. This project involved conducting detailed part teardowns and diagnosing failure mechanisms, specifically cracks and chips on the butterfly valve. A coworker invited me to participate in this investigation, where we analyzed a range of EGR valves in various states of wear. During these inspections, I identified a critical issue: the valves were opening to 100% regardless of the input provided in the user interface. To test my suspicion, I suggested entering a smaller value, such as 0.1, which revealed a coding error in the testing program. This error caused the input figure to be off by a factor of 100, which was promptly addressed to improve system accuracy.
In addition to my work on EGR valves, I managed and implemented a PowerBI dashboard for warranty part return data. This project required linking two separate databases containing over 50,000 individual claims, using Impala and Hue to integrate the data. The resulting dashboard provided an easily accessible and searchable tool, reducing data loading times by 50% and enhancing overall efficiency.
I also improved departmental project tracking by creating a streamlined one-page reporting format. This new system expedited project communication and coordination between U.S. and Mexico teams, showcasing my ability to lead cross-functional process improvements. These experiences allowed me to apply problem-solving skills, utilize data integration tools, and demonstrate leadership in driving process efficiency.