1. My Summer Internship Experience
Yesha Lester
Department 91: Machine R&D - Engine Drives Group
2. Introduction
• Yesha Lester
• University of Michigan
Sophomore in Electrical Engineering
PCI Chairman of NSBE
2nd year on Executive Board
• Department 91: Machine R&D
– Engine Drives group with Ed Enyedy
– Quality Team
– New Product Development
3. Hour Meter Project
• From Mechanical to Digital
– Hour Meter Malfunction
– Updated S17475-3 to a -8
– Reduces the number of
warranty claims
– $11,590 cost savings per year
Mechanical Meter
Digital Meter
Hour Meter
Data Mechanical (-3) Digital (-8)
Price Per Unit $8.12 $4.96
EAU 3244 8307
Faluire % 0.410% 0.012%
# of Warranty
claims 2012-
2016 41 3
4. Warranty Testing
• Control PC Boards
– Of the 15 weld control boards tested, 100% of the boards
were in good condition.
– Of the two power supply boards tested, one board failed
due to a shortage in the bridge rectifier.
5. Warranty Testing (cont.)
LED Meters
Of the 57 warranty claims, only 11 of the claims were valid.
Problems with the LED Meters:
• No Display
• Segment Display
Damage
• Incorrect Weld Output
• Display at Standstill
• Meter Fluctuating
6. Ranger Prototype Build Up: LCD Displays
• LCD Display
Testing
– Visual
Comparison Test
– Salt Fog Test
– Impact testing of
Controls
– Iron Powder Test
– IP67 (Waterproof
Test)
– Vibration Test
7. Other Projects
• Fleet 400 PC board mode change
– Arc Gouging mode update
• Code break for the Air & Non Air Vantage 600 SD
– Updated low idle RPM from 1400 to 1525
• Researched problems with stator lead variation
– Harness Redesign
8. Conclusion
• Learned how to read complex wiring diagrams and
schematics to find solutions
• Improved my communication and organization skills
• Gain knowledge about various engineering
disciplines (i.e. welding, mechanical and electrical)
• Learned how to troubleshoot and test FPGA boards
• Observed the manufacturing and industrial
processes of a company
• “There are no secrets to success. It is the result
of preparation, hard work, and learning from
failure.” -Colin Powell
9. Acknowledgements
• Ed Enyedy
• Amy McMullen
• Andy Meckler
• Patrick Donnelly
• Engine Drives Team
• Lee Seufer
• Will Wilder
• Brett Miller
• Interns
Special Thanks to everyone
who helped me along this
journey and assisted in my
learning experience here at
Lincoln Electric!
10. Thank You For Your Time
• Any Questions or Comments?
Editor's Notes
Notes:
Notes:
Mention how I am apart of the Quality Team and the daily scrum meetings. In those meetings, we discuss the projects that individuals are working on in the group to improve the quality of our department. One of my first projects were the Hour Meter Project. (Next slide)
Notes:
Discuss mechanical issues w/ the nuts.
After discussing the matter with the quality assurance team, I went to process a CRM to implement the change.
The digital meter has an annual usage of 8307 a year vs the -3 at 3244 per year.
Out of the warranty claims between 2012 and 2016, of the 44 warranty claims, only 3 claims for the -8 and the other 41 were the -3s. That says a lot considering the -8 has more annual usage that the -3.
The price of the -3 was $8.12 per unit
The price of the -8 was $4.96 per unit
Mention some of the claims on the boards.
Mention how out of the 57 LED Meters claims, only 11 were actually bad.
Mention how you did some of the testing.
Move LED Meter testing to another board.
Tested a chopper board too.
- Loose connectors may be the issue for why we are receiving back these great in condition PCB boards.
Discuss how I tested the meters and the outcomes of each.
Explain Each Test and the results.
Remember, you only have 10 mins total to present.
