General Motors

Overview: I worked at Brownstown Battery Assembly Plant, in Michigan. This plant has three main sections, Low Volume manufacturing (LV), Performance AWD Electric (PAE), and Autonomous Vehicle assembly (AV). Throughout my internship, I worked on projects with all three sections. 

One of my main projects for LV was to help the plant trial the manufacturing of a new type of battery module. I documented issues that occurred and led weekly meetings with engineers to solve those problems. I also collected cell scrap data on a daily basis and used that data to identify trending issues. With that data, I was able to suggest process changes to the manufacturing equipment, reducing the scrap rate. For PAE, my project involved the drivetrain for the Corvette Eray. I developed a process to effectively CMM the gears and case that make up the drivetrain. I created an Excel sheet that computed all necessary values. I conducted gage R&R studies to assure measurements were precise. For AV, I dealt with supplier-related issues, returning defected parts and coordinating quality checks. 

Outcome of experience: During my internship, I learned how a manufacturing plant operates and enjoyed the overall experience. I enjoy the manufacturing environenment because no two days are ever the same. Each day comes with new problems that require critical thinking and ingenuity to solve. I also had the opportunity to learn about the inner workings of the batteries in electric cars. Additionally, I had a lot of fun exploring Michigan's lakes and visiting Canada.

Skills developed

• Low volume battery & cell manufacturing
• Root cause analysis 
• Yield optimization
• Problem-solving
• Gage R&R & Capability

Fun fact: Michigan has the largest population of Arab Americans in the U.S. I had the opportunity to enjoy their culture through their amazing cuisine.