David Holmes
Grandville
Summary
Results-driven Manufacturing Engineer specializing in designing and implementing manufacturing equipment and automation for high-volume production. Expertise in mechanical design and fixture development, with a strong focus on cross-functional project leadership. Committed to delivering innovative engineering solutions that enhance safety, quality, and operational efficiency.
Overview
1
1
Certification
7
7
years of professional experience
Work History
Manufacturing Engineer
Challenge Manufacturing
Holland, MI
01.2026 - Current
- Designed packout line for 5-press tandem line to achieve 6-second cycle time, enabling manual packout by two operators during robot downtime. Engineered future-proof system for multiple part sizes and bin configurations while minimizing mechanical complexity and maintenance under $95K budget.
- Designed and implemented tooling, fixtures, and EOAT for high-volume stamping and automated production lines.
- Developed and maintained large-scale assemblies and plant layouts in SolidWorks, enhancing design efficiency and standardization across projects.
- Troubleshot mechanical and process issues on the plant floor, minimizing downtime and supporting continuous production.
- Collaborated with integrators and cross-functional teams to validate equipment designs and ensure successful system integration.
- Led continuous improvement initiatives to boost throughput, minimize downtime, and enhance overall equipment effectiveness (OEE).
- Evaluated capital equipment and automation investments through ROI and cost-benefit analysis.
- Created detailed drawings and documentation, including GD&T, to support fabrication and implementation.
- Implemented predictive maintenance and sensor integration efforts for improved equipment reliability.
Automation Engineering Intern
Challenge Manufacturing
Holland, MI
07.2024 - 01.2026
- Supported design and development of manufacturing equipment, tooling, and automation systems, enhancing efficiency for high-volume stamping operations.
- Designed and detailed end-of-arm tooling (EOAT), fixtures, and structural components for automation applications.
- Assisted in layout planning and optimization of welding cells and production lines, improving equipment placement and workflow efficiency.
- Assisted in layout planning and optimization of welding cells and production lines, including equipment placement and workflow improvements.
- Collaborated with engineering and maintenance teams to troubleshoot design issues and implement practical solutions on the plant floor.
- Generated detailed drawings, GD&T callouts, and documentation to support fabrication and assembly.
- Gained hands-on experience with manufacturing processes including stamping, welding, and automated material handling systems.
- Gained hands-on experience with manufacturing processes, deepening understanding of stamping, welding, and automated material handling systems.
Mechanical Design Intern
Commercial Tool and Die
Grand Rapids, MI
06.2023 - 08.2023
- Created a program for designers to input attributes from 3D models and calculate the minimum horn pin diameter for a slider block in any orientation.
- Established process to extract and sort attributes from AutoCAD drawings for fuse panels, reducing time spent searching for labels.
- Monitored early and late-stage production on injection molds to identify issues.
Mechanical Design Intern
TESLA
Grand Rapids, MI
08.2021 - 07.2022
- Project: Manage and research ways to develop temporary/soft tooling faster (13weeks R&D to Prod.).
- Researched FEA simulation and testing of materials to predict flatness of the draw die binder while underload Software used: Hypermesh, Hyperworks, CATIA GSA
- Developed an Excel sheet to convert data into a heat map for part tolerance, saving 2 hours per part.
- Managed data links between parts and assemblies in CATIA Desk to have a fully parametric design.
- Calibrated and ran 3KW 5 axis laser for prototype part material trimming
- Conducted weekly walkaround meetings with machinists and die builders to instruct on CATIA V5
- Implemented 5s factory layout to streamline workflow and enhance productivity. in AutoCAD and weekly meetings regarding the plant’s future updates.
- Compression of data for better performance and ease of access (Time saved: 45min per opening of assembly file)
- Updated soft tooling based on feedback from die makers and machinists to enhance production efficiency.
- Project: TGR press line for battery pack from prototype to full production line with Tesla BP
- Designed the full scrap removal on the main trim station.
- Designed electrical and press foundation layouts for production line hookups in AutoCAD.
- Worked with Tesla Brooklyn Park to integrate the scrap removal with the lift assist.
Mechanical Engineering Intern
Comprehensive Engineering
Grand Rapids, MI
06.2021 - 08.2021
- Developed detailed layout drawings for commercial and factory settings, focusing on HVAC, plumbing, and electrical systems.
- Created backlog program to distribute work among teams and track productivity effectively.
- Assisted in design and analysis of mechanical components using CAD software.
- Conducted testing and evaluation of prototypes to ensure performance standards.
- Collaborated with engineers to improve product designs based on user feedback.
Process Engineering & PDM Administrator Intern
Precision Aerospace Corporation
Grand Rapids, MI
06.2019 - 01.2020
- Project: Update HPMT cell, create deburring layout sheets, manage model operations in PDM
- Designed fixtures for high tolerance machining processes.
- Tracked model locations and assemblies, streamlining part reuse in other designs.
- Developed excel sheet that generated cam profile from 600+ points, saving 20-30 hours of design time.
- Fixture design for high tolerance machining.
- Collaborated with lead of deburring to create training manual for new employees.
Education
BS - Mechanical Engineering Technology
Michigan Technological University
Houghton, MI12-2025
Skills
- Manufacturing processes
- Manufacturing automation
- Process development
- Continuous improvement
- Lean manufacturing
- 5S implementation
- Production line efficiency
- Welding process optimization
- Simulation modeling
- Automation design
- SolidWorks design
- AutoCAD
- Facility layout
- Geometric tolerancing
- Design reviews
- Machine design
- Root cause analysis
- Failure analysis
- Cost strategies
- Engineering concepts
- Structural analysis
- OSHA regulations compliance
- OSHA fall hazard training
Certification
Certified Solidworks Professional
Timeline
Manufacturing Engineer
Challenge Manufacturing
01.2026 - Current
Automation Engineering Intern
Challenge Manufacturing
07.2024 - 01.2026
Mechanical Design Intern
Commercial Tool and Die
06.2023 - 08.2023
Mechanical Design Intern
TESLA
08.2021 - 07.2022
Mechanical Engineering Intern
Comprehensive Engineering
06.2021 - 08.2021
Process Engineering & PDM Administrator Intern
Precision Aerospace Corporation
06.2019 - 01.2020
BS - Mechanical Engineering Technology
Michigan Technological University