Globally Optimal Design Improvements to address Automotive Headlamp Condensation

Globally Optimal Design Improvements to address Automotive Headlamp Condensation

Condensation in automotive headlamps is a recurring issue throughout the industry which leads to customer complaints and warranty costs. Environmental conditions leading to condensation such as humidity and temperature can vary in different vehicle situations, seasons of the year, and headlamp designs.

Toyota seeks holistic solutions that improve our delivered product while considering the impact of any change along the entire product delivery process (materials purchase to dealer showroom). Any change must consider the impact of improved functional design against the impact on the end to end costs of delivery (i.e., material costs, manufacturing costs, risk, etc.).

The student team will simultaneously consider design changes for product improvement and the impact of any change on the entire organizational efficiency of Toyota. The Product subteam will focus on improving the technical design of the headlamps to reduce condensation; the SED/Supply Chain subteam will collaborate with the Product subteam to provide design for manufacturing feedback for Part and Process along with assessing the impact of proposed design changes on the cost and efficiency of the entire supply chain (purchasing, manufacturing, product delivery).

More Information: 2017-Toyota

All student participants on Toyota’s student team will be conditionally offered a summer internship/co-op position. The internship is not required. Any conditional offer of co-op employment will be contingent on students’ ability to meet all of Toyota’s co-op employment requirements:

  • Cumulative GPA = 3.0 or above
  • Ability to obtain/maintain employment authorization without Toyota’s sponsorship
  • Have your own reliable transportation to commute
  • Able to work overtime
  • Able to travel for business
  • Successful completion of a post-offer drug test and post-offer background check

Students who successfully match to this project team will be required to sign the following two documents in January 2017:

Student IP Agreement for this Project Team

2017 Student Non-Disclosure Agreement for this Project Team


How to Apply

Project Features

  • Skill level All levels
  • Students 5-7
  • Course Substitutions AUTO 503, GAME 503, MFG 503, ME 490, Honors, ECE Cognate, IOE Capstone
  • IP & NDA Required? Yes
  • Summer Opportunity Internship Guaranteed
  • Mechanical Design (2 Students)

    Thermodynamics, Heat Transfer, Evaporation and Humidity

    • Likely Majors: ME, ISD-AUTO, ISD-GAME
  • Electrical Engineering (1 Student)

    Circuits and Product Integration

    • Likely Majors: EE, CE, ECE
  • Supply Chain (3 Students)

    Supply Chain Analysis, Business Data Analysis

    • Likely Majors: IOE, BBA
  • Analytical Modeling (1 Student)

    Experimental and/or Analytical Modeling Skills

    • Likely Majors: ME, ISD-AUTO, ISD-GAME, STATS

Faculty Mentor: Line Van Nieuwstadtlin
Associate Professor of Engineering Practice
Line earned her Master of Electrical Engineering in 1989 from Cornell. She joined the U-M’s Space Physics Research Laboratory in 1999 after working in the Netherlands, and at NASA’s Jet Propulsion Lab, where she was a team leader for the Mars Pathfinder Microrover. She completed her PhD. in EECS at the University of Michigan in 2011.
Sponsor Mentor: Chris Grantchris
University of Michigan, BSME, MSME, Senior Engineer Body Design-Functional Parts
Additional Project Engineering Support: Sunil Dalal (Wayne State University, MSME, Senior Engineer, Vehicle Performance Development 1), Chelsea White (Purdue, BSEE, Engineer Electronic Systems 1), Bryan West (University of Cincinnati, BSEE in Electrical Engineering; Manager, Supplier Engineering Development), and Liz Delozier (University of Cincinnati, BS in Industrial Management; Senior Analyst, Purchasing).
Project Champions: Dan Neubauer (Purdue University, BSME, General Manager Body Design-Functional Parts), Madhan Ramaswami (University of Michigan , MSAero, MBA, Manager Vehicle Performance Development 1), Nick Sitarski (UM-Dearborn, MS Engineering Management, Manager Electronic Systems 1 ); Meg Wallace (Georgia Tech, MSME, Senior Engineer); Kim Engel (General Manager Supplier Engineering Development); Greg Laskey (General Manager Purchasing).
For More Information About This Sponsor, Visit Their Website (Toyota).