Tenneco | Mechanical Engineering Internship

Product Development · Lean Manufacturing · Design of Experiments (DOE) · Root Cause Analysis · Gage R&R 

Summer 2023

High Volume Parts Tray

One of the main problems I had to tackle during the launch of the new packaging machine was a high-volume parts tray. Under tight constraints, I encountered a challenge with an outdated parts tray that could only hold five plastic-wrapped parts. Determined to enhance efficiency, I designed a high volume parts tray capable of accommodating up to 60 parts, aiming to optimize production and address corner cases of overloaded volumes.

Working with another engineer and the maintenance crew, we crafted a durable, custom-made tray with non-stick surfaces and low friction roller. The design ensured secure containment and seamless retrieval of components during the packaging process.


Increased Production Capacity: The new tray allowed us to handle larger batches, significantly reducing lead times and meeting deadlines efficiently.

Streamlined Operations: Fewer interruptions and reduced manual interventions streamlined our packaging line, maximizing overall productivity.

Cost Savings: Enhanced efficiency and minimized waste led to tangible cost savings and optimized resource utilization.

Improved Quality Control: The tray's secure design minimized errors and damaged components, ensuring only top-quality products reached customers.

Before Roller

Prototyping Roller Brackets

After Roller

Anti-Static Bar

As the first to install a packaging machine of this kind in the building, we encountered an unforeseen challenge in the form of clingy plastic wrap on the conveyor belt. This caused disruptions and frequent maintenance, prompting us to explore solutions. A visit to another facility opened our eyes to the transformative potential of anti-static bars.

Anti-Static Principles at Play:

The Ion anti-static bars operate on the principle of ionization. By generating an electrical field, these bars prompt air molecules to break down into positive and negative ions. Opposite charges attract, and any charged material near the bar draws in ions until its charge is neutralized.

Transfomation of Final Packaging

Before: Wrinkled plastic, hard to read label

After: Smooth, glassy, clear

5S Workflow Optimization

Optimized the workflow using the 5S manufacturing principles: sort, set in order, shine, standardize, and sustain.