Toyota Internship — Production Engineering Co-op
Toyota Motor Manufacturing Texas | August-December 2025
As a Production Engineering Co-op at TMMTX, I applied Toyota's problem-solving methodology (TBP) to address assembly line quality challenges, designed and analyzed countermeasures, and contributed to digital twin analysis for install verification.
Highlight Project — Windshield Quality Defect (TBP)
Situation
100 + windshield defects recorded at TMMTX in 2025
Task
Apply TBP to eliminate all primer misalignment defects — a ~40% reduction in the overall gap.
Action
Conducted Genchi Genbutsu and a root cause analysis. Collected 100+ friction data points, measured rack gaps across 7 racks, mounted accelerometers to capture in-route vibration, benchmarked windshield retainment methods, designed a new rack with 1-way rollers and solid locating features, ran FEA to ensure design durability, and validated with physical deflection testing (−13% error).
Result
Created an actionable countermeasure and provided handoff documents. Gap was almost fully closed during my investigation process by a skilled maintainance member.
Widshield rack design concept.
Limit Switch Rail Fix
Situation: TMMTX's new rear axle line hoist had inconsistent limit switch engagement across its full travel range, creating a risk of the hoist entering the chutter area without triggering the switch.
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Task: Design a solution that achieves consistent limit switch actuation across 1900mm of travel while avoiding interference with existing rail structures, pneumatic lines, and electrical cables.
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Action: Benchmarked the current design, measured limit switch actuation force with a force gauge, and evaluated two ski bar configurations via a decision matrix assessing rigidity, levelness, packaging, and electrical compatibility. Modeled the selected design in Fusion 360 and ran an FEA, confirming rigidity and durability. Presented the full design process and solution on an A3 to the team. Worked with a contractor to implement countermeasure.
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Result: Delivered a compliant ski bar design compatible with existing hoist and rail structure, requiring no additional cable management and achieving consistent switch engagement across full travel.
3D Kamishibai & Leica Scanning
Built a 3D Kamishibai in Navisworks. Used Dusty Robotics and Leica scanner with Cintoo to compare as-built steel post positions to CAD.
Toyota Business Practice
FEA (Inventor)
3D Laser Scanning
Data Collection & Analysis
Technical Communication
Genchi Genbutsu
CAD (SolidWorks)
Navisworks