Greater Asheville
Rotation #3 - Manufacturing Engineering Development (MED) Program I supported high-volume casting operations through yield improvement, process optimization, and enhanced machine control initiatives focused on product quality and manufacturing capability. I reduced annual scrap costs by more than $4M by eliminating coating delamination occurrences through root cause identification using input/output correlation analysis and hypothesis testing methodologies. I collaborated with suppliers to revise processing methods and strengthened coating fixture controls to improve process consistency and reliability. I also improved process control by redesigning metrology fixtures to inspect features relative to a soft-nested airfoil datum structure, enabling fixtures to adapt to casting variation during grinding operations. Additionally, I increased datum communication fidelity between CMM systems and grinding equipment through RFID integration and mitigated product quality escapes through population bounding analysis and specialized rework processing strategies.
Rotation #2 - Manufacturing Engineering Development (MED) Program My primary project delivered Pratt and Whitney’s first model-based defined (MBD) component, the first step to enabling industry 4.0 manufacturing digitalization, comprehensive connectivity, and efficient design iteration. I initialized the process plan and carried out first article development within the legacy manufacturing execution system. I pioneered MBD consumption, validated future-state capabilities, provided user training, and authored best-practices. Through the utilization of my MBD tool proficiencies (NX suite) and geometric dimensioning and tolerancing (GD&T) training, I designed in-process CAD models to enable end-to-end digital connectivity, to support derivative programming, and provide definition to the shop floor for all downstream manufacturing processes. My success with this project demonstrated key capability for cutting edge advancement and earned my team RTX-wide recognition for our accomplishments. My second primary project, from which I earned my Lean Six Sigma Greenbelt, was a cycle-time reduction by turning a critical feature (~5” dia, +/-.0005 tol.) and eliminating a lengthy grind operation. Following preliminary data analysis and a gage R&R, I firstly strengthened my measurement system with a new, higher fidelity CMM program for the primary feature, better manual gaging methods, and enhanced on-machine probing. By leveraging the newly acquired process capability data, I was able to identify taper and circularity issues from the current state turning process. Perishable tooling optimization, NC program control enhancements, and cut sequencing improvements provided the adequate corrective action to turn the feature with a Cpk (process capability index) of >1.33, with an effective 99.99% FPY. Final results reduced overall cycle time by over one hour per part, with significant opportunity to implement similar improvements for other part numbers within the business unit.
Rotation #1 - Manufacturing Engineering Development (MED) Program My primary project was the launch of a comprehensive, searchable tooling database that streamlined data retrieval for the end user and would reduce manual effort by more than 100 hours annually across the business. Through Agile project management to develop and deploy enterprise software solutions improve operational efficiency and support future scalability. I led cross-functional teams through solution architecture development, product launch coordination, and user adoption initiatives to ensure successful implementation. I leveraged SQL and Power Query to extract, consolidate, and analyze historical tooling data from legacy systems and also authored standardized work documentation, delivered end-user training, and secured executive stakeholder sponsorship to support long-term operational integration and sustainability.
I contributed to the initial conceptual design of a large lighting fixture, estimated to generate approximately $22 million in sales from major retailers such as Walmart and Target. I made a significant impact on this project by initiating idea synthesis and analyzing Design for Manufacturability (DFM) per part for various manufacturing processes (injection molding and sheet metal). Additionally, I led a comprehensive market research initiative for this major retail project utilizing benchmarking analysis. I systematically dissected competitor products, strategically evaluating each with customer-prioritized metrics. By aligning my discoveries with the Customer Experience Matrix (CEM) and applying the Voice of Customer (VoC) perspective, I cultivated market-informed conceptual design and data-driven decisions. I drove execution in preparation for the launch of a project by building samples for regulatory testing and collecting electrical data efficiency certification. I also led an improvement initiative for installation instructions to increase end-user satisfaction and decrease the occurrence of installation failures. By inviting an electrical contractor to visit the facilities and participate in installation trials, I was able to collect valuable external feedback on the product and implement improvements for previously undiscovered gaps/deficiencies. Through my work on these and other products, I mastered my CAD proficiency and utilized best practices for design engineering. Notably, I ensured the successful placement of locating pins on an injection molded plastic part using Geometric Dimensioning and Tolerancing (GD&T) and conducted tolerance stack-up analysis for precise alignment. Furthermore, I actively contributed to data input and thorough analysis in conducting Design Failure Mode and Effect Analysis (DFMEA).
Operational support for jet engine compressor blade production I identified a disregarded opportunity to reduce waste and enhance the laser part-mark process for the F135 program. Then, I initiated a cross-functional discussion with project and process owners to determine what steps had already been taken and what additional investment was required to implement a solution. Once I was appointed to lead the project, I found a solution, changed the process, and confirmed the successful results with an internal lab. By implementing my solution, I was able to eliminate an extra operation and reduce production costs by approximately $51,000 per year. I redesigned a comprehensive real-time manufacturing analytics database that analyzed and monitored over 2000 key product characteristics/indicators for more than 100 part numbers. The database calculated Cpk values and other process capability metrics to ensure that the operations remained within industry-specified limits. I automated repetitive manual input tasks by coding Excel macros in Visual Basic for Applications (VBA). I increased the efficiency of the standard process by 25% and eliminated engineer down time.
I was responsible for the analysis of returned Home Depot products in the tools, hardware, plumbing, and roofing departments. I analyzed each product using root cause analysis, collected and compiled common defect and failure data, then reported my findings to the Home Depot quality assurance team for each department. In weekly meetings I would present the data and discuss possible process improvements that could be made for each product to prevent defects from reoccurring and increase customer satisfaction. I hosted a supplier visit once for APEX Tool Group, the primary vendor for Home Depot’s HUSKY brand power tools. In this capacity, I delivered a comprehensive presentation outlining my assessments and analyses of their products to APEX engineers. Subsequently, I engaged in constructive discussion to empirically determine the manufacturing process responsible for the identified defects. I fabricated multiple experimental testing modules to collect short-term performance data, to determine ease of installation and also to track the deterioration of products after long-term installation. I formulated a DMAIC process improvement project to improve the process for uploading media to the quality assurance team by installing a new cross-functional database. I earned Intern of the Month and also Best Presenter for the report out presentation to the Vice President of The Home Depot.
Engineering Intern (unpaid)- gained industrial knowledge via manufacturing projects - Collaborated with the engineering team on custom design challenges and urgent orders - Shadowed departments along the production line and observed the steps required before reaching the final product - Tested products to ensure that the dimensions were accurate, and the quality was up to standard