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Company Overview / Role Summary
Company Overview / Role Summary
The IFD Sensor is a factory-installed fault detector that gives crew a simple visual alert when an internal arc occurs in a distribution transformer. With the IFD Sensor, line workers stay safe when troubleshooting and get the lights on faster. - IFD
IFD Technologies is a Vancouver-based engineering company that develops innovative solutions for the electric utility industry. Their technologies improve safety, operational efficiency, productivity, and customer service for utility companies worldwide. I worked as a Product Engineer Co-Op from Jan. 2024 to Aug. 2024, where I contributed to various projects in mechanical design, manufacturing, R&D, and quality assurance.
Key Responsibilities and Projects
Key Responsibilities and Projects
At IFD, I contributed to a variety of projects, including designing mechanical jigs, investigating non-conformances, and implementing Lean Manufacturing practices. Through these experiences, I developed transferable skills in mechanical design and manufacturing.
Mechanical Jig Design
Mechanical Jig Design
Designed and maintained assembly jigs for production, optimizing production and reducing cycle time by 25%.
Selected materials and manufacturing methods to prioritize safety, durability, and efficiency.
Utilized 3D printing for rapid prototyping, enabling quick iterations and proof-of-concept validation.
Product Research and Development
Product Research and Development
Documented findings in 10+ academic papers and technical literature to effectively refine proposed product prototypes.
Analyzed test data from previous prototypes to identify key areas for product refinement.
Implemented design changes based on data analysis of tests and CAD simulations to enhance prototype performance.
Supplier Non-Conformance Investigation
Supplier Non-Conformance Investigation
Determined the root causes of 10+ non-conformances through data exchange and detailed communication with the supplier.
Assessed the severity of non-conformances using statistical analysis and CAD simulations to predict potential impacts.
Developed and presented a corrective action plan to be implemented by the engineering and manufacturing teams, ensuring alignment with established quality standards.
Quality Control Plan Implementation
Quality Control Plan Implementation
Developed 30+ comprehensive quality control plans to ensure suppliers met established quality standards and to minimize product defects.
Identified and emphasized 100+ critical dimensions to be inspected, preventing product non-conformances and ensuring consistent quality.
Established standard operating procedures (SOPs) for incoming inspection of components, using statistical process control (SPC) to track and control process variations.
Key Takeaways & Skills Gained
Key Takeaways & Skills Gained
Technical Skills
Technical Skills
Design and Simulation Tools: SolidWorks, 3D-Printing, Rapid Prototyping, Hand Tools
Quality Control & Manufacturing: Statistical Process Control (SPC), Lean Manufacturing, Root Cause Analysis, Supplier Management
Data Analysis & Documentation: Statistical Data Analysis, Technical Writing, Academic Research & Documentation
Soft Skills
Soft Skills
Problem-Solving: Root Cause Analysis, Investigating and Troubleshooting
Project Management: Scheduling, Time Management, Milestone Tracking, Resource Allocation
Communication: Technical Writing, Stakeholder Presenting and Reporting, Project Documentation
Supporting Materials
Supporting Materials
Seen above is an example of a jig I've created, made to cut our components to their necessary size. This jig is vital for our line, as we were not comfortable with our operators having to use open blades to manufacture our components.
Below, the CAD of this jig is shown to show the complexity of the components designed, including the integration of an arbor press bought off-the-shelf.
Arbor Press
Completed Jig
My final design came with numerous improvements from my initial design, such as:
A spring-loaded system ensures that any blades are biased away from the operator’s fingers
A wheel and rail movement system, decreasing the effort needed to operate the jig
Alignment features, leaving the operator no doubt that they would be cutting the parts correctly
This design became machined, and is now the jig we use today!
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