Cogenra uses rows of mirrors to concentrate light onto a strip of photovoltaics (PV) to generate electricity.  Simultaneously they circulate water behind the the PVs to collect the waste heat.  They can then use this hot water for other needs the customer might have (showers, industrial process, etc.).  

One of the projects I worked on during my time there was to develop a new way of attaching the mirrors to the solar tracking frame.  The previous version required installers to crawl underneath the frame and screw into the sheetmetal structure that supported each mirror.  My task was to reduce the installation time as much as possible.  

Working with other members of the team I developed a C shaped roll formed sheet metal structure that allowed the mirrors to be snapped into place.  The assembly time for the mirrors was reduced by 67%.  

During the design process I continually ran tests to make sure that the new design would go on easily, couldn't be blown off in high winds, and that if the glass broke that the pieces would still be safe.  

I worked with a roll forming factory to set up a high volume production line and traveled to the mirror factory and worked directly with them to set up a robotic assembly line for attaching the mirrors to the sheetmetal frame.