Electrical engineering co-op student Luke Laforest received a Rising Star Award for his contributions during a work term at Ford Motor Company's Windsor Engine Plant. Through projects focused on predictive planning, assembly-line optimization and continuous improvement, he delivered solutions that helped improve efficiency, reduce costs and support frontline workers. (LUKE LAFOREST/University of Windsor)
By Victor Romao
At a modern engine plant, even a brief disruption can have significant consequences.
Keeping production moving requires constant problem-solving, careful planning and collaboration among employees across multiple departments.
During a co-op placement at Ford Motor Company's Windsor Engine Plant, University of Windsor student Luke Laforest found himself working on projects that addressed those challenges firsthand.
From helping prevent costly production interruptions to improving assembly-line processes and supporting frontline workers, the experience demonstrated how engineering can create measurable business results while making a difference for the people behind the work.
For the third-year electrical engineering student, the placement provided opportunities to contribute well beyond the responsibilities typically expected of a co-op student.
Among his most significant projects was the development of an engineering forecasting tool designed to help predict material requirements and reduce the risk of production disruptions.
He also contributed to assembly-line optimization initiatives, continuous improvement projects and cost-saving efforts that affected operations across the plant.
His work earned him a Rising Star Award from Co-op, Career and Experiential Education, recognizing outstanding co-op students.
In this Q&A, Laforest reflects on the importance of people-centred engineering, the value of taking initiative and how his Ford experience reshaped his career goals.
Q: What was the most significant learning experience during your co-op placement at Ford Motor Company?
A: The most rewarding part of my placement was learning how direct and practical engineering can be when it comes to helping people. As part of a Kaizen event sub-team working to reduce waste and cycle time, I spent a lot of time on the floor analyzing the assembly process and noticing areas where operators were dealing with unnecessary reaching and strain.
I was able to communicate with the operators directly and put new measures in place on the line, such as reducing reach distances and optimizing workstations. The gratitude the operators showed me was incredibly rewarding. Something that was such a small part of my day helped improve their shift every day. It showed me that even small-scale, everyday improvements can make a significant difference.
Q: How did your co-op experience contribute to your personal and professional growth?
A: This co-op experience allowed me to grow both personally and professionally by changing how I approach my work. Instead of waiting for instructions from my supervisor, I learned to actively seek out my own projects and drive my own improvement.
If I could think of an idea that could be a cost savings, reduce cycle time or give us better data, I was completely free to do it. Having that level of freedom to innovate not only made me a much stronger problem solver, but it also taught me how to take true ownership of my role and work effectively toward the team's common goals.
Q: What achievement from your work term are you most proud of?
A: One of the projects I'm most proud of was developing the Engineering Forecast - Journal Grade Analyzer. After a near material shortage threatened significant downtime on the engine line, I created a forecasting tool that shifted our planning process from reactive to proactive.
The system helps predict material requirements before shortages occur and provides teams with better information for planning. Presenting the project to senior leadership and seeing its potential for implementation at other Ford facilities showed me how a single idea can create a meaningful impact across an organization.
Q: Did the experience influence your future career or educational plans? If so, how?
A: Yes, it absolutely has. I actually went into university believing the automotive sector wasn't the right fit for me. However, working at Ford completely shifted that perspective.
Seeing just how many different departments operate within an assembly plant, and realizing how dynamic the day-to-day work can be, really solidified and changed my career goals. I found it incredibly rewarding to apply on-the-job learning to real challenges on the plant floor, which ultimately led me to take on a part-time position after my co-op.
Right now, I'm exactly where I want to be, focused on finishing my degree while maximizing my impact and growing with the team at Ford.
Laforest's experience demonstrates how experiential learning enables students to apply classroom knowledge in meaningful ways while contributing to real-world business objectives.
Through projects focused on innovation, efficiency and continuous improvement, he gained valuable technical and professional experience while discovering a career path he had not previously considered.
Today, he continues to build on those experiences through a part-time engineering role with Ford while completing his degree.
This article is part of a series celebrating excellence in experiential learning and recognizing Rising Star Award recipients selected by Co-op, Career and Experiential Education.
Employers interested in hiring a co-op student can contact hire@uwindsor.ca