Redesigned the cowl vent grille (also  known as leafscreen) for the Ford Fusion when a major water ingestion issue was discovered at the prototype stage.  The biggest challenges of this redesign were the following:

• The water ingestion needed to be resolved while still complying with the air ingestion requirements of the HVAC team.
• The redesign has to account not only for the North American version, but also for the European left and right hand drive versions
• The impact to cost and timing for the vehicle program due to the changes had to be minimized