d_ED2_FINAL_A3

Approved Approved Checked Checked Prepared Date

5/18/2007Daniel Sheline - TTC ED2 470L Cabin Design

I. PURPOSE

Reflect on ED2 Co-op experience & summarize projects and skills gained

III. OBJECTIVES

Bring a high-energy positive attitude

Apply classroom knowledge to projects

Understand departmental responsiblilities and procedures

Strengthen my desire to have a career in automotive design

Improve CATIA skills Implement the Toyota Way in daily activities

Gain engineering design experience Support ED2 470L design team

VI. CONCLUSION & REFLECTIONS

Spring '07 Sum '07 Fall '07 Spring '08 Sum '08 Fall '08 Spring '09 Sum '09

ED2 VPD1 Undergrad TTCStudy

AbroadUndergrad

Graduation

Semester!Full Time

Fall 2004 - Fall 2006

Undergrad

V. CONCLUSION & REFLECTIONS

Ù Ù

Ù Ù

Ù Û

Û Ù

Improved CATIA skills

Gained engineering design experience

Bring a high-energy positive attitude

Implemented the Toyota Way in daily activities

Supported ED2 470L design team

Understand departmental responsiblilities and procedures

Applied classroom knowledge to projects Strengthened my desire to have a career in automotive design

II. STUDENT BACKGROUND INFORMATION

College: University of Michigan

Major/Minor: Mechanical Engineering / German

Graduation Date: May, 2009

Co-op Term: ED2 January 8th May18th, 2007

Project: Support 470L team through mid-GENZU, GENZU, & mod-GENZU

IV. PROJECTS (Continued)

Project Skills Attained

3. Objective

- Hide A-Plr Garnish from outside view

- Minimize the effects of the ceramic on visiblity

- Create an even appearance between the

Garnish line and ceramic line

Method

- Utilized PDCA

P: Benchmarked Headliner & A-PLR Garnish for

Normal 044L W/S and Pano 041L W/S

D: Designed 470L A-PLR Garnish & Headliner ceramic with the same

relationships as 044L Normal and 041L Pano W/S

C: Confirmed with ADA that appearance is acceptable

Confirm that ceramic effects on visibility are minimized

A: After ADA approval, implemented ceramic into next design stage

4. Objective Method

- Learn to analyze data, work with -Attended 2 week training session

assemblies and create drawings -Completed 6 CATIA lessons

-learn basic functions of Sketcher

and how to develop surfaced parts.

5. Objective Method

- Support ED2 engineers to reduce their workload -Made copies, illustrations drawings, sections,

benchmarked vehicles, & mass releases on ProMASS

-Performed other miscellaneous tasks

6. Objective Method

- Propose cost & mass estimate for GENZU -Cut 25 sections on 470L

- Hole location use of expansion foam -Made a drawing displaying sections

A-PLR

Garnish &

Headliner

Ceramic

Design

Description

-Gained

knowledge of

ED6 parts

-Improved my

CATIA GSD

skills

-Learned how

to manipulate

parts within a

CATIA product

Improved

CATIA drawing

skillsGFF GENZU

Locations

CATIA

training

Learned basic

functionality of

CATIA design

platforms

General

Document

Management

Experienced

company

administrative

programs

044L A-PLR garnish &

ceramic relationship

041L headliner &

ceramic relationship

Proposed 470L side

& top ceramic

IV. PROJECTS

Project Skills Attained

1. Objective

- Maintain same electric power density as 180L

- Accommodate 470L Wiper park position & glass edge

- Use structure with De-Icer printed on

inner surface of outer W/S glass

Method

- Utilized PDCA

P: Benchmarked 180L & 500N De-Icer sections

D: Implemented 180L section based on common structure

C: Confirmed wire screen print feasibility with suppliers (AGC & ULN)

Dimension A NG, suppliers require a 5mm pitch between W/S edge & wire

A: Repositioned pattern for distance A to be a minimum 5mm

2. Objective

- Hide mirror button and EC mirror wire

housing from outside view

- Commonize ceramic patterns to

reduce cost (~$0.57)

- Reduce number of W/S variations

Method

- Utilized PDCA

P: Benchmarked 044L & 180L EC & Prism

Mirror ceramic pattern sections

D: Implemented benchmarked ceramic pattern relationships and apply Prism

Mirror to save on screen printing and W/S variations

C: Confirmed with ADA that the mirror base and wire housing are

hidden from outside view

A: After ADA approval, implemented ceramic into next design stage

Windshield

Wiper

De-Icer

Pattern

Design

Description

-Gained

engineering

design

experience

-Gained

knowledge of

ED1K parts

Inner Mirror

Windshield

Ceramic

Pattern

Design

-Improved

CATIA skills

-Learned to

communicate

with suppliers

-Practiced

Toyota process

of PDCA

-Improved

CATIA section

cutting skills

-Learned how

to be cost

conscisus by

optimizing

designs

A

A

Section A-A

Ceramic commonized

to EC screen print.

EC mirror

section Prism

mirror

section

A B STATUS

13.3 12.3 Ù

2.7 6.5 ×

5.0 4.2 Ù

470L Initial

470L GENZU

180L

Model

Cowl to fender seal

shelined@umich.edushelined@umich.edushelined@umich.edushelined@umich.edushelined@umich.edushelined@umich.edu