RYAN ZERNACH

Full-Stack AI Systems Engineer

Ryan_Zernach_2025_Senior_AI_Systems_Engineer_Remote_United_States

🏭 Panduit | Mechanical Engineering Internship

In Summer 2011, I worked as a Robotics & Mechanical Engineering Intern at Panduit in Cumming, Georgia. Founded in 1955 and headquartered in Tinley Park, the Chicago-area manufacturer employs thousands worldwide. Its scale made the lesson immediate: a plant is not a collection of stations; it is a system where every handoff has consequences.

Related Links
Panduit Company Profile
Panduit Cumming, GA Location
Panduit

Summary

This internship gave me a ground-level view of a global manufacturing operation: materials, equipment, process, people, and decisions all moving together. Plastics, conveyor flow, extrusion-style production, warehousing, shipping and receiving, CAD documentation, and cross-functional execution stopped being separate topics and became one operating system.

Internship Snapshot

Panduit · Robotics & Mechanical Engineering Internship · Cumming, Georgia · May 2011 - September 2011

Deep Dive

The details below trace that system from material flow and production to a CAD fire-protection walkdown and the LEAN/Six Sigma habits that made improvement practical.

Supply Chain, Conveyors, Warehousing, and Shipping/Receiving

Manufacturing speed comes from system coordination

Plastics + Extrusion-Oriented Production Learning

Material behavior drives engineering decisions

CAD Fire Safety Infrastructure Mapping Project

Documenting reality across a massive facility

Mechanical Engineering Meetings, LEAN, Sustainability, and Six Sigma

Process rigor and leadership under operational pressure

What Walking The Floor Changed For Me

The CAD documentation project took me through most of the building and into conversations with people at their stations. It changed how I think about engineering: a design must be technically correct, but it also has to be clear to operators, maintainable by teams, and durable through a real shift.

From Classroom Theory To Plant Reality

Before this internship, plastics, conveyors, inventory, CAD, quality, safety, and leadership lived in separate mental folders. At Panduit, I saw them compound into one operating system. That systems perspective still shapes how I approach engineering work.

Takeaway

Panduit was an early turning point: drawings needed to survive reality; processes depended on people; small decisions carried operational consequences. That mix of technical depth and floor-level context has stayed with me ever since.