Francisco Xavier Soria

Research and Development Intern

Ossur Americas

06.2024 - 06.2025

Supported the development and validation of injection molding processes and tooling, including the application of scientific molding principles and execution of IQ/OQ/PQ protocols.
Generated technical reports to communicate findings from prototype evaluations, material trials, and molding process studies.
Performed assembly testing for new product prototypes, contributing to early-stage feasibility and process development.
Collaborated closely with the New Product Introduction (NPI) team in the development and optimization of new medical components and processes.
Provided cross-functional support to Manufacturing, Quality, and Engineering teams, assisting with prototyping, troubleshooting, and continuous improvement initiatives within the R&D scope.
Performed root cause analysis (RCA) using tools such as 5 Whys and Fishbone diagrams to address nonconformities and recurring process issues.
Gained foundational knowledge in machining and mold/fixture fabrication, supporting the design and review of basic tooling and inserts used in molding and assembly processes.
Contributed to the planning and execution of engineering projects, including timeline tracking, resource coordination, and documentation.
Supported the creation of detailed technical reports, including process documentation, test results, and root cause analyses for process deviations.
Participated in continuous improvement initiatives aimed at reducing cycle time, minimizing rework, and enhancing process robustness.
Participated in PFMEA sessions to identify potential failure modes, assess risk priority numbers (RPN), and propose corrective actions for process improvement.