I. CAD Parts & Drawings

• Created new CAD parts, revised components as needed, and adjusted assemblies accordingly (including debugging any part interferences)
• Updated drawings with revisions and notes to then be handed off to manufacturers
• Identified a need to re-organize our CAD database of parts, assemblies, and drawings to ensure consistency in tracking components across teams (and developed a new system that directly synched with our BOM)

II. Root Cause Analysis

• Worked through DRM (design for manufacturing) challenges to prepare our product for harsh environments
• Conducted field failure analysis, followed by evaluating and vetting various solutions
• Tested failure modes and validated solutions to help develop successful product
• Quickly prototyped and mocked-up models/filters to assist with material and product quality control on the manufacturing line
• Specific issue areas included: the joint between the cast aluminum down-tube and the composite deck/neck, carbon fiber wrap de-lamination, tire wheel wells, etc.

III. CNC Test Fixture

• Created a CNC flat lid fixture for manufacturers to help validate product quality
• The fixture acted as a “go/no go” gauge to dictate whether a lid met our flatness standard and ensure quality control quickly
• Derived the shape from the body of the scooter and adapted it for efficient CNC machining

IV. Bill of Materials (BOM)

• Identified opportunity to make BOM more efficient when communicating across cross-functional teams (engineering, management, manufacturers, etc.)
• Created a master BOM and locked certain areas so only specific personnel could edit
• Coded sheets to auto-generate custom BOMs to meet the needs of each cross-functional team

V. Dynamometer

• Outlined and built an in-house dynamometer to assist with motor data collection
• Designed to collect torque and RPM data directly from a torque sensor rather than a tachometer
• Designed all machined components and built the industrial table myself
• Click here for more information about the “dyno”