Charles Pixley completed a production engineering co-op from January to August 2015. During this time, he submitted numerous PCNs and RCNs to improve processes, submitted regular reports and analyses to track production data, and designed and implemented various organizational systems. He also acquired skills in CAD software, maintenance systems, tool tracking, and industrial power tools.

1. 2001 EAST TERRA LANE • O'FALLON,MO. 63368 • 636-240-2400 •FAX 636-240-2506
Charles Pixley
cwpg2d@mst.edu
314-488-3067
Production Engineering Co-op: January 5, 2015 – August 11, 2015
Planned Graduation: December 19, 2015
End of Co-op Report
PCNs
 Evaluated, tested, and submitted a PCN to consolidate the holes in the light pan that would
provide more consistency, save time, and move the hole outside of the baffles, which cuts down
the amount of condensation
 PCN for adding silicone hosing to some copper on TDBD-48-2s to protect it from hitting other
metal
 PCN that corrected a piece of the liquid line that would eliminate the need of a copper elbow and
thus make the brazing process easier on TDBD-96s
 PCN that involved researching and finding the best option for replacing nails with screws on
TSID/TBDB
 T-Series Cabinet Bottom Notch Adjustment PCNs (multiple) that will prevent foam leaks and
increase the ease of the build
 PCN that would correct a ballast box in Bowling Green to eliminate wasted punches and thus
wasted time
 T-Series Back Support PCN to remove wasted cuts and thus wasted time
 PCN that involved changing the gasket bases on GDM10/12 models that would remove
unnecessary notches due to the new top-mounted hinge system
 Developed and submitted a PCN that would substitute the blue foam for a new white foam that
should save the company over approximately $30,000 a year. Along with the savings, it also
prevents condensation better than the currently used blue foam. This PCN also sparked some the
incorporation of the new foam into the horizontal mullion redesign, so it will go on to save even
more money and be more effective.
 Developed a PCN that added silicone to a repair kit to help with the aesthetics of
TWT/TUC/TSSU. It removed the application of the silicone on the line and assigned that to the
repair workers out in the field. This prevents the silicone from drying out and being hastily
applied.
 Created new prototype crossrails for TDBDs that have pre punched holes which would save time
and effort for the line workers while improving consistency. This PCN included changes to the

2. crossrail backup back bottom, cabinet over step rail, cabinet back center,crossrail bottom back,
and the compressor housing back side of step.
RCNs
 12 different RCNs that involve moving condensing units around
 Currently working on a final RCN that will move every remaining unit still registered on 07145
away from the now shut down line
DATA
 Until a critical file error happened that is still unresolved, I submitted weekly foam reports for
most of the lines in the company
 Generated and distributed daily labor reports that helped supervisors keep track of how they were
doing throughout the week in BG
 Created a spreadsheet calculator for 4172 that would take in cabinet seam measurements and
generate data on whether there was an acceptable amount of foam leakage
 Created a more effective series of cover sheets for work instructions that made finding things
much simpler in BG
 Standard work (recording/marking times) on 4380
 Recorded the entire process of a T-23HC being built
 Tape audit on 0611, 0612, and 0920
 Performed a return on investment study on buying a new upender for 0713
 Performed an in-depth return on investment on the dry ice guns, that supported the decision to
continue on and purchase more
 Performed a study on the rate of loss for dry ice using an in-house cooler, a Yeti, and an Igloo, in
order to see which would provide the best value
 Generated an estimate of the total volume of certain coolers per customer request via Doug Koch
 Performed a series of scans and gathered data, analyzed it, and helped bring about the conclusion
that the Cosma was starting to work properly, and that the previous fix (new bristles) was a
possible solution
 Performed tool audits on multiple lines to help implement the Gigatrak Tool Tracking software
 As a follow-up on the PLC Interface design, I calculated the cost of all of the currently used
equipment that will be replaced once the new setup is implemented
 Calculated the total cost of shooting foam bags every day including the traditional foam guns and
the Cannon system
 Evaluated B.A. Fan locations and submitted my ideas for suitable locations
5S/Maintenance/Water Jet
 Designed and had made a vertically adjustable brazing stand for 4175
 Designed and had made a set of carts designed to hold coolers for the dry ice guns.
 Designed and had made a series of Job Qualifications Matrix Stands (along with regularly
printing out the matrices)
 Designed and had made metal numbers for Burton to use during the foaming process.
 Created a plastic trim storage rack for IDL that conserved space,while increasing organization
 Designed a ball transfer lift that went unused due to maintenance solving the issue themselves
 Created a backscreen rack for 4376 that would prevent them from taking a hit on their BPAO
audit, while at the same time getting pieces off of the floor, giving every type of piece (NRP

3. included) a space,and increasing organization
 Replicated custom spacers and designed a rack to hold a notcher that was being transferred from
4381 to 4380
 Designed and had made a universal jig switch holder for BG
 Created official PP numbers, designs, and made a consolidated list for the 10 templates used at
Evap Install on 4381
 Designed and had made a cart for IDL that would allow ease of access while preventing the
containers/totes from being removed too easily
 Designed and had made T-72 shelf templates as requested by Ken L. from Burton C. from Doug
K.
 Designed and had made a template for the correct application of the True nameplate on TBBs,
although that process was abandoned
 Designed a specific quantity cart for the counterweights that have started being used on certain T-
series
 Designed and had made a table that intentionally limited WIP, while conserving space,and
increasing versatility with the ability to flip the fan holder over to revealanother style of holder
 Created a louver rack for 4172 that saved space,and got many pieces off of the floor
 Created a table extension for 4172 to store the counterweight holders
 Designed and created a wire holder for Matt Bowen
 Designed and created a wire tester for Ken L.
 Custom copper storage cart that conserves space by playing to the shapes’ strength, while also
getting the pieces off of the floor
 Created a door storage divider that would fit in the preexisting rack,but ultimately that plan was
abandoned
 Helped design and construct an overhanging tool center for a production line
 Improved upon a design for a one piece hand-broken cabinet end support for T-Series that would
allow it to also work on slide door models
 Altered a prototype cabinet leg support Chris Moonier made that allowed it to fit into slide door
models
 Designed an Evap Install template that combined three templates into one. The template has a
specific radius bend and thus hasn’t been formed due to worries about forming it from the sheet
metal department.
 Created a prototype TFP-64 back that included the movement of some holes, while also allowing
easier access for maintenance over time. I ran out of time to perform full tests on it, but the new
co-op has the pieces.
 Formed and had made half of a system that would allow a horizontally expanding table to also
expand vertically. The design has been changed and now Andy in BG is working on it.
 Formed and had made slim lifts that could be put on top of preexisting foam carts that would
allow the coolers to be slid in and out of the foam jigs more easily, and prevent more damage
from dings. Handed off to Andrew Odle when I transferred to BG.
Miscellaneous
 Created standard drawings for Kanban copper container lids
 Performed tests with a power hose-spreader to see if it was a viable option for the line
 Evaluated and drew up flat back caps for T-19/23/35, although that idea ended up being
abandoned
 Researched and purchased a GoPro camera,created an easy to use guide for it, and tested it on the

4. Cosma
 Created an official PP number for jig inserts on T-series
 Designed a font that can be used on the waterjet more effectively than the default stencil
 Created models of multiple Kanban containers for Jason Barth and submitted them
 Created an official drawing for LAE Box brackets
 Fixed a spacer on 0307
 Added tabs to certain cabinet back caps for powder coating uses
 Created PPs for door backs on TSSUs and TPPs that are easier to use, more aesthetically
pleasing, and less likely to come off
 Designed the basic layout for a user interface between the line operators/foam team and the PLC
that controls the foam guns
 Started designing a rack for 4376 UPS Packing Hood and Lids, but the PCN that attached those
parts to the EBOMs took too long to go through for me to make any more headway
 Researched an issue with the shelf standards on 4381, but the company decided to approach the
issue in an alternate way
 Helped start the redesign process of the GDM-47RL/TSD models
 Trained Ty Elley to perform work related tasks (create SPCNs,RCNs,use Solidworks, etc.)
Miscellaneous Skills Acquired
 Solidworks
 JDE
 Ensur
 Maintenance Connection
 Gigatrak Tool Tracking Software
 DraftSight
 General Industrial Power Tool Handling
 eDrawings
 Parts Inquiry