Mechanical Engineering – CA Work Experience Program

Intuitive Day 1 – Rohen and Tymur

Today we began with a tour of the office, starting with their workshops and testing spaces for mechanical and electrical engineers. We saw how their surgery robots worked and the designs they had used, including the evolution of their technology since the 90s. We learned how to control the robots and we were able to use on to perform tasks that are used for testing, such as tying a wire.

The robots are extremely simple to use, it only took a few minutes to get used to the controls and start doing more complex functions. Afterwards we toured their refurbishing facility where they take older generations and turn them into the new robots.

Day 4 at Caterpillar Inc

Today was our last day of the work experience program. I really wish we had more time! We met at the Sanford Facility, where they produce skid steer loaders in large quantities. We first met up with Mr. Kareem Gad and Mr. Austin Flint — they are both electrical engineers. They gave us a quick presentation on the different machines they produce at the plant — after going over safety rules, of course. We then put on our safety glasses and some headphones and went to the assembly plant. Mr. Gad toured us around the plant — he spoke through a microphone that attached to our headphones because it was so loud. Lots of different machines are being moved and worked on at once, prompting the need for headphones. Once again, I can’t describe a lot of what I saw — for confidentiality — but I attached some pictures I found from the internet (searching “caterpillar assembly”) that look similar. I was amazed by the raw scale of the plant — the Sanford plant is famous for its speed and efficiency. Mr. Gad and Mr. Flint showed off their different machines — just produced from the plant and being tested in their testing facility. After touring the Clayton facility, it was really interesting to see how it is done in a different facility. We then met with some people involved in fabrication at the plant — Mr. Morgan Timney is a design engineer helping out with the fabrication process and Mr. Jimmy Wood is the production manager. Mr. Wood gave us a presentation on the fabrication process and taught us about welding. They then gave us a tour around the Fabrication Plant — once again, confidential, so I attached photos from searching “caterpillar welding.” The Fabrication Plant was really cool — I have never seen anything like it before. We were once again reminded of the amazing skill of manufacturing engineers (from our first day at Caterpillar) observing the efficiency of the plant.

After having a really fun lunch at Fat Junior’s (Mr. Combs actually joined us during lunch!), we went back to the facility to learn more about design and test engineering at Caterpillar. We learned more about the engineering design process and were shown examples through some CAD drawings of different parts of their machines. I have attached a photo as an example of the design process. One of the difficulties of design engineering is creating a stable, efficient, and easy to assemble product/part/machine. Testing helps an engineer identify problems with a design — endurance testing, for example, can help them identify areas of high stress where the material may yield. We were given a presentation on the different types of stress applied to an object. We were given a paperclip and told to tug it, bend it, and break it. To break it, we had to bend the paperclip back and forth multiple times — this is an example of fatigue. The presenter was an analyst who created engineering simulations. The simulations show areas of high stress as a result of load — these areas of high stress may need more support to ensure that they do not yield. Mr. Gad and Mr. Combs also enjoyed the presentation and brought up some interesting questions and topics of conversation — the huge number of different variables that must be taken into consideration in design engineering is truly amazing. They remember learning many of the things we talked about in college — every course and lesson really does have an important real-life application. The simulations were really impressive — I have attached a photo and video as an example.

We then went back out to the testing facilities. Like we did on our second day, we got to test a strain gauge. This time, it was attached to more flimsy steel, so Matthew, Atticus and I had a little competition trying to bend it — we were able to compare the results on a graph afterward (I lost). We also got to see the strain gauge on an actual machine and learned about what it was measuring. We then returned to the building for a 3D visualization presentation and demonstration. I’m not sure how much I can reveal about that, but basically, we were able to look at a machine with a virtual reality system — I have attached a video. We ended our day there — we gave out some gifts and then left the building. We were all really sad to say goodbye to Mr. Combs, Mr. Gad, Mr. Flint, and Caterpillar in general. My experience at Caterpillar has made me confident in my desire to pursue engineering — maybe one day I will return as an intern in college!

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Day 3 at Caterpillar Inc

Today was our second and last day at the CMDC. Mr. Combs picked us up from the front lobby (we gave him our gift and thank you notes) and took us to our respective mentors for the day. My mentor was a design engineer working on backhoe loaders. She showed me some of her work on CAD and taught me about the different steps she takes while designing parts for the machines. She explained how a hydraulic cylinder works (it’s really cool!) and emphasized the importance of effectively collaborating with people in other departments. She also took me to see the hydraulic cylinder working on the machine in real life. I really appreciate everything she taught me — I am definitely more certain of my interest in design engineering. We then gathered back together (after giving some gifts to our mentors) and met with two electrical and software engineers. They gave us a presentation about the newest automated machines being produced by Caterpillar — it was really fun to learn about this side of engineering. They showed us some of their prototypes and then took us to operate one of the machines! Atticus, Matthew and I moved the machine in a figure-eight around two cones, and Mr. Combs (it was his first time operating the machine too) not only moved the machine around the two cones but also knocked a rock off the top of one of the cones. Being in control of the machine was a bit stressful (I was worried I would break something) but also really awesome! The recent developments in automated machines are really exciting — I feel like I have seen a glimpse of the future!

After operating the automated machine, Mr. Combs took us to a field with a backhoe loader and a mini excavator. Mr. Combs and one of Caterpillar’s expert operators taught us about each of the controls in the machines and how to safely operate them. Matthew and I then took turns operating the two machines — it was really fun! It was also interesting to control and see the machines after learning more about the design process — after learning about the different parts and processes needed to create the machines, each motion seemed more significant.

After lunch, Mr. Combs introduced us to a design engineer who was also in charge of 3D printing. He gave us a presentation about the process of engineering, from initially getting an idea to producing the final product, and taught us about some of the procedures and difficulties involved in the overall process. He then gave us an engineering challenge — we had to brainstorm ideas to solve an issue with the design of one of the machines. He showed us how he would process and print a design with the 3D printer, and took us to see the 3D printer itself in action. After giving our gifts and thank you notes to Ms. Hill, we said our final goodbyes and left the CMDC building for the last time. I learned so much and really enjoyed my time with the workers of Caterpillar’s CMDC. I will never forget all of the things I saw and experienced — Thank you so much for this amazing opportunity!

Day 2 at Caterpillar Inc

Today I was able to arrive at the Clayton Machine Development Center problem free (thanks to my early accidental sneak peek yesterday morning). Matthew, Atticus and I met Ms. Viviane Guessi and Mr. Collin Walther for the first time — they are both currently working as test engineers.

Side note: Many of the people I met and shadowed were part of a program in Caterpillar called ERDP — Engineering Rotational Development Program. In this program, people are able to rotate through different departments. They are able to explore and figure out which department they would like to work in permanently, while also building a network with people in other departments. Mr. Walther and Ms. Guessi are not permanently working as test engineers, but are currently in that rotation.

First, we were given a thorough safety presentation. We learned about the different alarms, exits, emergency equipment, and how to stay safe around the machines. Mr. Walther and Ms. Guessi then gave us a presentation on the different products being made and tested at the site — backhoe loaders, small dozers, mini excavators, small skid steer loaders, etc — and they taught us about the different machine groups, engineering roles, and facility capabilities. After the presentation, we suited up with our vests and safety glasses and went out to tour the fields of the facility. I can’t reveal a lot of what I saw — for the company’s privacy — but Mr. Walthers gave us a very interesting tour. It was really amazing to see the massive machines up close and to see how they test them — I have a lot of respect for the machine operators. After the tour, we came back to the main building and three of Caterpillar’s model interns gave us a presentation on how to prepare for college/internships and how to get involved in college. It was a really helpful talk — I will definitely keep their advice in mind while touring colleges and building my applications over the rest of the summer. I really enjoyed hearing about some of the programs they are involved with at their schools — engineering racecars with formula SAE, finding friends and making connections with the American Society of Mechanical Engineers and the Society of Women’s Engineers, and even just branching out and getting involved in sports teams and Greek life. I really appreciate them taking the time to share their own experiences! After their presentation, Ms. Guessi took us to a different room and assigned us an Engineering Challenge. We were tasked with building a bridge over a 40 cm space between two tables with only dry spaghetti, rubber bands, and a little bit of masking tape. We had to make the bridge stable enough to hold up multiple books. Matthew, Atticus and I had a few disagreements at first, but after a lot of discussions, we were finally able to agree on a design. We created a couple of thick bundles of spaghetti held together with rubber bands and arranged them to fit between the two tables. We had two bundles held together on top of two smaller bundles (for stability) in the middle. We designed the bridge for the string holding the bucket of books to attach from the two opposite sides of the bridge — after testing it out, this bridge was incredibly stable. But, we then learned that we had to attach the string from the middle instead. This was a little concerning, but after testing the bridge in a legal way, it held up with all of the books. Even after adding all of the extra weight they could find, it only collapsed after overbending (and slipping from the tables), but the bridge itself stayed intact — a complete success! It was a really fun and rewarding experience.

After lunch, Ms. Guessi and Mr. Walther gave us a presentation on test and development. We got to learn about the different tools they use to test their machines and the different ways they measure and record data. Mr. Walther taught us about some of the things they measure in tests and showed us the kinds of calculations they make based on the measurements. Ms. Guessi then let us play around with a steering cart hooked up with different sensors. Following her instructions, Matthew put in the necessary parameters and changes, and we were able to see the live measurements and recordings from the sensors on the cart. We got to tinker with a strain gauge and pressure sensor — we turned the steering wheel (which either applied pressure to the left or right, measured with a yoyo) and tried to bend a piece of steel (the strain gauge measured the tension and compression). After tinkering with the sensors a bit, Mr. Walthers took us back out to the fields to watch him do some testing. It was really fun to watch him work — he also talked with us and gave us a lot of useful advice for engineering.

It was an educational and fun day — we got to see (and get into) some of the action of the more hands-on side of engineering. Thank you, Mr. Walthers and Ms. Guessi for teaching us so much!

Day 1 at Caterpillar Inc

Today was my first day shadowing at Caterpillar Inc. After struggling a bit to find the correct building (PSA: don’t always trust google maps), Atticus, Matthew and I started the day off at the Clayton Assembly Plant. Ms. Melissa Hill introduced us to the company, giving us some basic information about the plant and the machines being assembled at the plant. Then, Mr. Jake Combs and Ms. Elizabeth Schappell took us to a conference room and gave us a presentation on what they do at Caterpillar and how they became mechanical engineers. I really appreciate the time they took to present the information to us–I was able to learn about the different classes they took at NCSU and the real-life applications of those courses in their jobs at Caterpillar. They also gave us some advice on exploring the different fields of engineering and finding jobs after getting a degree. It was a really informative and useful presentation — Thank you so much!

We then suited up in yellow vests and went out to look at some of their products. They were in the process of doing Product and Application Training at the site — their marketing managers were teaching their dealers about their products. It was really interesting to learn about the different parts and functions of their machines and to see how they presented them. Mr. Combs and Ms. Schappell also taught us about the machines we saw — a Backhoe Loader, Small Wheel Loader, and Skid Steer Loader — telling us how they worked, and the kinds of processes they used to create and sell them. After exploring a bit, we went in for some pizza.

After lunch, we got some protective glasses and headed off to explore the actual assembly plant. Mr. Ryan Spies, a manufacturing engineer, took us through the assembly line, explaining how each machine and process worked and describing some of the projects he had been working on to make the process as efficient and safe (Caterpillar always stresses the importance of safety!) as possible. I can’t share a lot of information or pictures because some of the products and machines are secret, but I really enjoyed learning about the machines and seeing them in action — Matthew, Atticus, and I couldn’t hold back our ‘Ooos’ and ‘Aaahs’ while watching the workers and machines in action. After touring the plant, Mr. Spies showed us his drawings — the way he thinks and solves problems around the plant is truly incredible. His job seems to be a bit of architecture, mechanical engineering, and general management combined. He also showed us how their information is organized and shared on their company sites. We ended the day there — Thank you so much for letting us follow you around today, Mr. Spies!

Day 4 at Apex Tool Group

Today was my last day at Apex Tool Group. I started the day off with Ms.Stone — we visited Mr. Scott Kolodziejski, who I spent the second part of the day with. We returned to her office, where she organized and planned out topics and things she would have to work on during her business trip next week. She also showed me some of her spreadsheets that she had created. She taught me about the different kinds of information she had to keep and organize — costs, parts, tests, and more. She also showed me a presentation created by the sales team, who went out and interviewed prospective customers, getting information on what things they liked and didn’t like. It was very interesting to see the different kinds of information she had to consider and fix to create the best possible product. She then took me to the warehouse, and showed me some of the products they had created and tested. It was really fun to think about the different components of all the products — how they could be fixed, how they were beneficial, what they had to change and work around. She also took me to the packaging part of the warehouse, where I was able to see all of the conveyor belts and machines that process and sort packages that are received and delivered from the warehouse. Before lunch, I had some spare time to give out thank you notes to everyone who worked with me. I then went for lunch at Mr. Dumpling with Matthew, Cecil and another one of our office neighbors (Ms. Stone sadly wasn’t able to come).

After lunch, we returned to the office and Ms. Stone took me to Mr. Kolodziejski. He toured me around his lab and taught me about the different testing equipment — what they do, how they work, and how they are useful. Some of their testing equipment was created by the workers of the company themselves, so I can’t share pictures of them, but I got to see and learn about a lot of their different machines. I particularly enjoyed learning about their salt fog chamber (I have attached a picture of it below), which tests the corrosion of their different metals and products. Mr. Kolodziejski taught me about the importance of limiting the variables while testing, and explained to me how their machinery (for example, their very precise and complicated drop test machine) ensures the accuracy of their tests. I also enjoyed visiting their Met lab, where their materials are tested on a more microscopic level. I learned about some of their machines that take microscopic pictures of their material, and then allow them to measure the distance between different points on the image. I also learned about one of their machines that tests for what materials actually make up the product by creating a spark and analyzing the particles that come from the spark. I found these machines very fascinating— it’s impressive that the company takes such small details into account when they are making their products. We returned to the main lab, where I was able to watch some of the workers testing and inspecting their products. I was also able to help them with a hardness test — I had to place the product onto the machine and tighten the hold until the machine gave the reading. It was very interesting to see this more active and tangible side of engineering — I enjoyed watching them test and work out different problems to look for ways to improve their products.

I returned to the office with Ms. Stone for the last time. Ms. Stone gave me some final advice on finding jobs and choosing career paths before we parted. Thank you for everything, Ms. Stone! Matthew, Mr. Wilson and I took pictures, and Mr. Wilson told us about how he first got into mechanical engineering and why he loves it. Thank you, Mr. Wilson! I then left Apex Tool Group for the last time. I am so grateful for this opportunity — I really enjoyed shadowing in and exploring the many different different departments within the company, and seeing the wide reaches of engineering in real life. I really thank my many mentors at the company for teaching me about their jobs and sharing their stories.

Day 3 at Apex Tool Group

Today, Ms. Stone took me to Ms. Jessica Greene, a packaging engineer. She showed me some videos about packaging programs being taught at Michigan State (where she went for college) and Clemson. She also talked to me about her experience interning and working at different places as a packaging engineer— she has worked for General Motors, BMW, Rubbermaid and many other companies. One of the most important things I learned from her is the necessity of organization, especially as an engineer. She shared with me her carefully created excel spreadsheets for her schedules and projects — I certainly hope to one day reach her level of organization! She showed me some of her responsibilities and challenges as an engineer: designing dielines (packaging templates), choosing the best material for the packaging, simulating and inspecting package transport, communicating with and combining ideas from the many different departments within the company. After showing me some of her dielines, she took me to the design department, where I shadowed Ms. Christina Opel. I was able to see and better understand the design aspect of packaging. She was working on printing out different labels for some new products— some of her main responsibilities are drawing icons and designing the packages in accordance with the needs of the packaging and marketing departments. Along with designing the packages, Ms. Opel also had to form models by hand, printing out the labels, cutting them, and pasting them onto foam or poster board to manipulate them into a shape similar to what is actually created and sold. Ms. Greene then took me with her to pick up a package she had received from China— she had to check the products and packaging. She gave me a lot of useful advice for finding internships and exploring different careers to find a niche. She then gathered her colleague Zach and manager Mr. Steve Hoskins, and had them introduce themselves and tell their stories of how they got into packaging and how they ended up working for Apex Tool Group. I am very grateful for all of the advice she gave me, and for everything she did to show me the different aspects of her job and different journeys taken to find jobs in general. I was very impressed by the wide range of departments she had to work with, and by the intricacies involved in packaging — choosing materials, designing the shapes/types of packages, and organizing the order in which packages are sent and processed.

After lunch, I met up with Ms. Donna Armocida, who is a project manager. She has a lot of different responsibilities, and mainly works on organizing and setting the pace of the different projects she oversees. She first gave me an overview of how the projects at Apex Tool Group are organized and pushed forward — with different tasks that need to be completed by specific dates, and presented to management/administration. She also taught me about the different challenges that a project may face, how that affects the schedule, and how she would try to overcome them. She gave me a lot of insight into how the wheels of the company turn — I was very impressed by the level of organization and communication that she preserves and supports. To help me understand the many complicated components of the schedule, she gave me multiple examples of different projects she has worked on or is currently working on — I was truly blown away by how much work she has done and how many products she has helped create! After showing me some of the products and projects being created/processed in the company, she took me to two meetings for two different projects she was supervising. I was able to see and better understand the challenges that come up in engineering and business in general— especially in international relations. I enjoyed learning more about engineering and its ties with business and communication. I was really impressed by Ms. Armocida and her work — I hope all of her projects work out smoothly!

A lot of what I saw/learned/worked with involved products and information that I shouldn’t publish online— I instead have attached pictures of the building (which I haven’t posted a picture of yet), and some snapshots of the videos I watched with Ms. Greene.

Continue reading Day 3 at Apex Tool Group

Day 2 at Apex Tool Group

Today, I spent the day exclusively shadowing my main mentor Ms. Heather Stone. I started the day off checking the details of some of the drawings — checking that the gages were correct for each part and component. Ms. Stone was working on placing a label on her product. She was fiddling with different colors, sizes, and placements. As a quick break, Ms. Stone took me into the warehouse area, where we met Matthew and Mr. Wilson walking back to the office. They made a U-turn to show us what they had been looking at — the old engineering drawings from the company records. It was very interesting to look through the drawings that had been made by hand — especially after working on the CAD software and creating computerized images. After looking around, Ms. Stone took me back to the office and brought me with her into a phone meeting. Their meeting was very interesting and enlightening. I must admit that I didn’t understand a lot of it — due to the advanced lingo and professional discussions– but I was able to see a surprising side of engineering. This was the first of a handful of different phone meetings Ms. Stone had throughout the day, and I was able to see the more collaborative and business-y side of engineering. I was once again impressed by the wide range of different skills and responsibilities that engineers have. For example, Ms. Stone also had to book a flight to Tennessee for the next week — I learned that she travels fairly often (every few months) for her job. At the end of the day, I helped Ms. Stone edit and fix typos from the drawings that we had marked earlier in the day. She also worked on completing tasks that came up in her meetings — updating information on costs and materials, talking with people in different departments/levels, completing and sending out different visuals for her products. Shadowing Ms. Stone, I was able to better understand the daily life of an engineer. I am incredibly grateful that Ms. Stone let me follow her and listen in to her meetings, explaining terms and discussions that I didn’t understand. Thank you, Ms. Stone!

Additionally, throughout the day I was very fortunate to receive some cool gifts and goodies. Mr. Thompson dropped by to give me the completely finished 3D print and metal carving of the flanged nut we created yesterday. Thank you again, Mr. Thompson! I also received my own craftsman caliper. I was thrilled, being able to check the real measurements of the flanged nut models (they were pretty exact!). I also received a Husky cap from Ms. Yessie Ortiz, who is in charge of the mail and company store — thank you so much! It was a very rewarding day in many ways. I thoroughly enjoyed being able to see the everyday routine of an engineer with Ms. Stone and being able to feel like a real engineer with my own caliper. Once again, I am very grateful for these opportunities given to me by Apex Tool Group and their kind employees.

Day 1 at Apex Tool Group

Today was my first day shadowing at the Apex Tool Group. I was a bit nervous at first, but after meeting many of the nice people working there, I am now only excited for the days to come! Matthew and I started the day off with a tour around the building. We got to greet many people working in different departments — there were departments for engineering, design and packaging, machinery, human resources, management, and more. I was very impressed by how massive the building (and company) was, with so many different people with different specialties working together to create their products. After the tour, I shadowed my main mentor, Ms. Heather Stone, as she was checking the labels and information on drawings for her products. I was very happy to be able to help — we had to look for typos and spots where information was missing or the drawings were overlapping the boundaries. Ms. Stone also checked over the dimensions and labels on the drawings. She very kindly (and patiently) taught me how to fix the mistakes on their main CAD software, Creo Parametric. We then went out for lunch at Panera with Mr. Welch, Matthew, and Matthew’s mentor Mr. Cecil Wilson. After lunch, I met up with Mr. Bob Thompson, a Senior Pro E Technician. He is an expert at using CAD software — he taught me how to create 2D and 3D drawings from scratch. We started by measuring all the dimensions of a flange nut. Mr. Thompson then showed me how to create a 2D drawing of the side view of the nut. We then moved onto the 3D software, which is much faster and easier to use. While I say that it was “easier” I simply mean in comparison to the 2D software — creating drawings is incredibly difficult and intricate work. Drawing the flange nut would be considered easy and basic work by Mr. Thompson, but I would have taken days trying to do it by myself. Luckily, Mr. Thompson speedily got the work done, creating the drawing I have attached below. While the attached drawing seems to be 2D, it is actually 3 different perspectives of the 3D drawing Mr. Thompson created. I contributed in only small parts, but still felt incredibly proud of and amazed by the end product — to me, the drawing is a work of art. After creating the drawing, Mr. Thompson showed me how to format the drawing to send off and be 3D printed. We moved to the machinery room, where Brett adjusted the 3D model and simulated its creation with the metal carving machine. Mr. Thompson also started the 3D printing of a plastic version of the product — created with layers of resin. Brett started the process of carving the flanged nut from a block of steel — I attached a video of the machinery at work (it’s very cool). Sadly, we had to cut the printing and carving short, but I was still able to see most of the final product. The 3D printed nut was also mostly finished, so Mr. Thompson rinsed it off with a high-pressure rinser (which took off the outside layer of resin) and gave it to me along with the drawing we had created. Mr. Thompson showed me one of the most beautiful aspects of mechanical engineering — seeing your ideas form into 3D models, and then seeing those 3D models built as real and functional products. I learned so much from Mr. Thompson and everyone I met and talked with throughout the day. I would definitely consider pursuing mechanical engineering to someday create more CAD designs — thank you so much, Mr. Thompson! I am very excited to see what other skills I may learn in the days to come.

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Day 4- Explanations

Yesteray Dr. Hotz explained how the Gas Chromatograph worked and I’d like to share the specifics of the essential piece of equipment I worked with here.

Looking at the key, there are a multitude of essential parts to this machine. Distilled into a user’s guide, the two coils in the center (inside the oven) are constantly carrying gas through the machine and out the back. When the measurement is engaged, the sampler (1), which feeds the coils, switches off and prevents any more gas to enter. This gas is then heated. The coil is coated with an absorptive substance that the gasses stick to. As the gas mixture is heated and the particles separate, different gasses detatch from the coating at different times (once they have reached the heat necessary unique to the molecule). By measuring the time at which the gas molecules detatch in the detector (4), we can tell which gasses are in our final composition i.e. what reaction took place, how much reacted, and what the yield in terms of energy will be.