EGR 290 Co-op Experience
Eric
Experience Information
Employer: Flexfab LLC
Job Title: Product Engineer: Heavy-Duty Truck Department
Major: Mechanical Engineering
Received Credit: Yes
Paid: Yes
Abroad: No
Description of the Organization
Flexfab is one of the world's top manufacturers for high performance silicone hoses and polymer compounds. This company was started in 1961 in Hastings, Michigan and they now have over 1,000 employees. In addition to their Michigan locations, they also have locations in Europe, South America, and China. Flexfab is made up of four different business units: Heavy-Duty Truck, Automotive, Aerospace, and Locomotive. This diversification helps create a consistent revenue stream regardless of market fluctuations.
Description of the Tasks/Projects Completed
During my internship at Flexfab, I worked with four other engineers and I had a large role in multiple projects. My first task was to learn daily activities such as quoting, part setups, and how to process engineering change-orders. I was also a part of several large-scale projects. One of the projects I was tasked with was to create a new expander tool for use in the company's 204-4-5 value stream. Flexfab has traditionally used pneumatic expanders, but these have now been deemed obsolete with the inception of the new expander I designed and tested. This project utilized knowledge obtained in both EGR 209 and EGR 309, primarily to ensure that it would stand up to the cyclical loading induced on it by the production line. I also submitted prototype testing requests which helped to familiarize myself with the industries and OEM's specifications.
Skills/Knowledge Gained Through The Experience
The specific skills that I learned on the job revolve around the special manufacturing principles that are required to create a silicone hose that will last one million miles on the road. Pressure vessel calculations are often performed to ensure the correct number of fabric plies are integrated into the hose. If this crucial step is not performed, the engineer risks either failing a performance test or having their product fail in the field. The flexibility of a hose is also considered, and often requires that the customer provides and determines the relative movement of the two connected components on the actual vehicle. In order to compensate for different levels of movement, I created a software in C++ that analyzes different convoluted profiles to determine if the engineers design is adequate for the relative movement specified by the customer. I also learned about the PPAP submission process, PFEMAs, supplier deviation requests, DVP&Rs and many other OEM mandated processes required for ISO 9000 certifications.
Favorite Part of the Experience
My favorite part of the co-op experience was that while working at Flexfab, you see a project through from start to finish. It typically started with a phone call from a customer service representative in the field that explains a potential application for a silicone hose. Quick feedback is often necessary to ensure that the representative is not wasting time on a potential lead that will go nowhere. This level of knowledge requires years of experience and technical know-how. Eventually, the lead turns into a request for a quote, where a detailed print is coupled with an annual usage estimate which can be measured in feet or number of pieces. An engineer then estimates the cost of the specified component and awaits feedback on whether or not the business is awarded. Once awarded, the engineer has to set the part up so it can be produced in a manufacturing environment in large quantities. This often requires tooling set up, work instruction setups, and sometimes, the conceptualization of a new piece of machinery to ensure the operators bodies are not subjected to strenuous activities. Being able to own your project in its entirety is what I like the best about working at Flexfab.
How the Experience Influenced Future Career Goals
My boss, Derek, has greatly influenced my career goals. He is a great person to work for and I can only hope that one day I will obtain his ability to allow employees that report to him to strive in their own ways. He always knows when to step in and lend a hand, and often offers up advice or technical experience that can help lead you to success. He also maintains the ability to communicate with customers and has begun to teach me how to navigate the nuances of talking to a salesman in comparison to talking with an engineer. In the future, I hope to learn more from him and maybe even take on a managerial position within the company.