Daniel Fernandes Borrego

Objective:

• First, strengthen the mechanical R&D team to deliver a pre-production of 1000 smart water meters in the very short term. Make the design more robust to limit manual operations on the assembly line and reduce the non-conformance rate.

• Then, in a second phase, prepare the industrialization of the product at a rate of 300k units per year.

• Complete review of the in-service project to minimize scrap rate. (solutions by design or process)

Achievements:

• Research and design of solutions to limit scrap rate and ensure product delivery

• Review of drawings and 3D models internally and with suppliers

• Statistical tolerance chain / Monte Carlo calculations

• Component optimization for cost reduction

• Design of test and rework tools for non-conforming parts

Results:

• Implementation and support of the engineering department around a tolerance chain calculation template and guidance towards the use of best practices for drawing definition (ISO 1101 etc.)

• Implementation of solutions reducing scrap rate with ROI <12 months

Plastic injection design engineer (Estella consultant at Molex, Bièvres) for hybrid and modular automotive harness connectors:

• Design of mating assist components, multiple outlet wire dress cover

• 2D/3D review

• Engage and follow up FEA and moldflow simulations

• Direct communication with Italy, US and Chinese plants (test lab/ manufacturing/simulations)

• CAD: Siemens NX / PLM: Teamcenter

• Application engineer, debugging of the traction control system (TCS) at BOSCH in Drancy, main client PSA. Debugging traction control on eCMP projects (eP21, eP24 eD34 eC41) and EMP2V3 PHEV v2. (P51/52 D41 E43) Tests and validations on high grip in France (Juvincourt) and low grip in Sweden (Arjeplog-Vaitoudden)