Tenaris Internship Writeup

Internship Overview

In Summer 2024, I completed an operations-focused internship with Tenaris McCarty, a leading global manufacturer of steel pipes for the energy industry. The McCarty facility in Houston is one of Tenaris’s key U.S. plants, producing small and large bore pipes through advanced manufacturing processes such as swaging, premium threading, and finishing. During my internship, I was responsible for identifying inefficiencies in production, analyzing traceability systems, and developing practical solutions to improve workflow reliability.

This role provided me with direct exposure to the fast-paced environment of large-scale manufacturing, where quality control, traceability, and efficiency are critical to meeting customer demands. I worked closely with both engineers and operators on the shop floor, which gave me a well-rounded perspective on how engineering decisions translate into daily operations.

Project A: Improving Traceability Reliability

A major challenge within the facility involved the traceability of pipes exiting Building D. Each pipe is assigned a data matrix (similar to a QR code) that records its movement through the facility, ensuring customer quality standards are met. However, pipes were frequently receiving incorrect QR stickers, leading to mismatched traceability data and potential customer claims.

To address this, I analyzed the existing system where operators used scanners and tablets to verify sticker accuracy. The process required manual correction whenever mismatches occurred, slowing throughput and increasing the risk of human error. My revised solution streamlined verification by tightening the link between the sticker printing system and the Level 2 data matrix tracking system, reducing rework and significantly increasing reliability at the small-bore exit line.

Project B: Applying Additive Manufacturing in Operations

My second major project focused on using additive manufacturing (3D printing) to address smaller but persistent inefficiencies within the facility. While not large enough to justify major capital projects, these issues impacted workflow, ergonomics, and reliability for operators. By applying CAD modeling and rapid prototyping with a commercial-grade 3D printer, I was able to design, iterate, and implement custom solutions quickly and cost-effectively.

Feeler Gauge Tool

I designed and fabricated a customized feeler gauge tool that allowed operators to quickly select the correct gauge size, streamlining the inspection process. By reducing the time spent searching for and organizing gauges, operators were able to perform quality checks much faster and with greater efficiency. This tool directly improved workflow while maintaining consistency and accuracy during inspections.

Tablet Shade Screen

Operators frequently struggled with poor screen visibility when performing traceability checks outside in bright sunlight. To solve this, I designed and fabricated a lightweight tablet shade screen that blocked glare and improved visibility. This solution ensured that operators could verify traceability data quickly and accurately, reducing delays and errors caused by environmental conditions.

QR Code Tags for Safety Inspections

I created a series of QR code tags that were placed at various points around the facility to provide operators with quick digital access to safety inspection forms. Previously, these inspections were recorded only on paper, which was inefficient and difficult to track. By scanning the QR tags with a tablet or mobile device, operators could instantly access and complete the correct digital form, streamlining documentation and improving the accuracy and reliability of safety records.

MRP Gauge Holders

I designed and 3D printed custom MRP gauge holders to give operators a safe, designated place to set down the gauges between inspections. Without proper storage, the gauges risked becoming uncalibrated or damaged, which could compromise accuracy during quality checks. These holders protected the gauges while keeping them readily accessible, improving both the reliability of measurements and the overall efficiency of inspections.

Skills and Lessons Learned

During this internship, I gained valuable experience at the intersection of operations, manufacturing, and engineering technology. I strengthened my technical skills in CAD design and additive manufacturing, using 3D printing to develop practical solutions that improved efficiency on the shop floor. I also built a stronger understanding of traceability systems in a live production environment, learning how reliable data and quality assurance directly impact customer satisfaction.

In addition to technical growth, I developed important problem-solving, teamwork, and communication skills. Collaborating with engineers, supervisors, and operators taught me how to design solutions that were not only technically sound but also aligned with the practical needs of daily operations. This experience showed me the value of small, targeted improvements and reinforced the importance of adaptability and collaboration in a fast-paced industrial environment.

My time at Tenaris was a formative professional experience that reinforced my interest in manufacturing and mechanical engineering technology. It gave me the chance to apply technical knowledge to real-world challenges, develop solutions that directly improved operations, and see firsthand how engineering innovation contributes to efficiency and quality in a large-scale industrial setting. This experience deepened my passion for pursuing a career in engineering where I can continue to apply creativity, precision, and problem-solving to drive meaningful improvements.

Final Presentation

Tenaris Final Presentation.pptx

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