Process Engineering at Shape Corp
Stephen
Experience Information
Employer: Shape Corp.
Job Title: Process Engineer Intern
Major: Mechanical Engineering
Received Credit: Yes
Paid: Yes
Abroad: No
Description of the Organization
Founded in 1974, Shape is privately owned and has four sister companies and more than 2,100 associates globally. Shape is known for designing, manufacturing, and testing automotive energy management systems which include bumper beams and energy absorbers. They also have injection molding capabilities for the automotive, furniture, and medical industries.
Description of the Tasks/Projects Completed
I worked with a group of process engineers that focus on improving the roll form process. Specifically, this means increasing utilization by decreasing downtime. I worked on the "cutoff" part of the process where the bumper beam is cut to a specific length. I learned this process is a lot more complicated than it sounds. I did a time study that analyzed downtime due to blade changes. I installed new technology which made blade changes 7.4 times faster. I did a controlled study which analyzed two blade cutting technologies: Laser-cut and EDM machined blades. I looked at the performance of each blade type as it relates to blade wear and part quality. I worked on other continuous improvement projects focused on the cutoff process. The main project I worked on was to install a piece of equipment on every necessary roll form mill globally (approximately 30 total). I wrote the technical user's manual which explains how to order, install, operate, troubleshoot, and maintain this piece of equipment. This equipment is currently being purchased and soon to be installed on mills in Mexico and Grand Haven.
Skills/Knowledge Gained Through The Experience
I significantly improved my project management, communication, and logical thinking skills. I learned the correct way to perform a controlled study in a manufacturing environment. Because most of my projects/studies were ran on 1st, 2nd, and 3rd shifts, I learned how to clearly communicate information to operators, engineers, and managers (three very different groups of people with very different personality types).
Favorite Part of the Experience
My favorite part was learning how to connect to operators. In a manufacturing environment, the last thing an operator wants to do is take orders from a young intern. I was able to get on good terms with most of the operators, which made performing my studies/projects much easier. Also, I played COD Black Ops with them outside of work which was fun.
How the Experience Influenced Future Career Goals
My goal as an engineer is to prove myself to be an engineer with solid work performance, in order to work for a successful company for many years. This experience confirmed that Shape is a good company to work for long term because there is a lot of opportunity and they have a wide range of manufacturing capabilities that a lot of industries demand. I would be happy to work in the automotive industry.