OVERVIEW________________________________________
Manufacturing Engineer with over thirty years experience in process improvement implementation, engineering group leadership, integrated technical team leadership, research and development science, lean manufacturing, configuration control, production line support and manufacturing planning development. Employment has been with the world leader in solid rocket propulsion systems successfully developing and implementing multiple breakthrough designs/processes for numerous governmental man-rated (NASA) and military (DOD) aerospace programs. Strengths include project implementation, team development/leadership, designing experiments, root cause analysis, proactive corrective action implementation, SPC, evaluating hardware performance, customer relations and written/verbal communications. Strong work ethic repeatedly recognized with individual and team performance awards for strong enthusiastic work ethic and ability to manage large workloads and multiple responsibilities simultaneously.
AREAS OF EXPERTISE________________________________________
• Engineering Development & Leadership
• Integrated Product Team (IPT) Leadership
• Project Engineering/Management
• Manufacturing Planning (Resources & Instructions)
• Configuration Control (Technical Documents)
• R & D Science (Process Development)
• Facility & Tool Design
• Cause/Corrective Action (ECAT)
• Critical Process Variable Reduction (CPVR)
• Process Failure Effects Mode (PFEMA)
• SPC Process Control (Statistica)
• Project tracking/scheduling (ACCESS)
• Concurrent Planning Audits (PPIA)
• Lean Manufacturing (TPS & PES)
• Electronic Documentation Control (ePIC)
• Electronic Planning Change Control (ESI)
• Electronic Shop Floor Planning (SFII)
• Design Concept Case Studies
• Kaizen Evaluations & Implementation
• Decision Focus (Problem solving)
• AutoCad
• Bills of Materials
• Cost Savings
• Quality Control
• Time Studies
• Tool Engineering
• SolidWorks
• Efficiency Studies
• IDEAS
• Six Sigma
EXPERIENCE________________________________________
COOKE ENGINEERING
April 2009 – Present (4 years 2 months) Ogden, UT
Contractual Engineering Consultant (2009-2013)
Implement lean manufacturing principles for continuous process improvement and quality systems techniques to monitor and resolve production problems. Develop R & D test plans, process specifications, qualification plans and technical management presentations. Implement manufacturing planning system to maximize communication of designs/processes to end users, eliminate planning errors and streamline sell-off of technical documentation of deliverable hardware. Develop applicable integrated product/process teams to resolve problems and prioritize proactive improvement projects to area specific design and process issues. Develop configuration control system utilizing proactive scheduling and concurrent engineering review methods of technical document development and review eliminating scheduling delays and hardware discrepancies associated with potential rework and errors. Implement effective daily operational support meetings and methods for resolving production issues by expediting identification of root causes and implementation of corrective actions eliminating discrepancy re-occurrences. Implement system to create, control and access all technical documents and planning from any authorized PC station.
ATK
October 1978 – March 2009 (30 years 6 months) Brigham City, UT
Senior Configuration Control Manager (2007-2009)
Responsible for final approval of all designs, specifications, manufacturing plans and technical presentations for the NASA Space Shuttle Reusable Solid Rocket Motors (RSRM) & ARES Space Launch System (SLS) programs resulting in the elimination of potential configuration errors and associated delays from document rework and hardware discrepancies. Developed and implemented continuous improvements to the technical document control system utilized plant-wide by all ATK RSRM/SLS configuration control specialists and engineers resulting on time release of error-free documents, improved technical presentations and a significant increasing in the approval rate through senior management Configuration Control Boards (CCB).
Integrated Product Team (IPT) Leader (2005-2007)
Developed, organized and led the RSRM/SLC nozzle assembly Integrated Product Team (IPT) consisting of multi-disciplined engineers, lead technicians, production support and quality assurance personnel resolving area specific nozzle assembly problems and implementing proactive improvement projects. Assigned coordinated team action items and reporting progress to senior management. Team consistently exceeded safety and quality performance goals and led all IPT’s plant-wide throughout ATK in the successful implementation of proactive “continuous improvement” projects.
Engineering Group Leader (2003-2005)
Expedited the development of manufacturing engineering groups consisting of inexperienced engineers and technical planners successfully overcoming a high turnover of skilled engineers and managers providing critical production support for the Space Shuttle RSRM nozzle program concurrent with the design/process development support resulting in two successful nozzle static tests SLS ARES Constellation program. Coordinated and expedited all engineering training, provided individual coaching and assumed additional engineering and project responsibilities as required to meet all performance goals and original NASA contractual scheduling milestones.
Project Engineer, R & D Process Development and Senior Manufacturing Engineer (1994-2003)
Championed the development and implementation of multiple large scope process improvement projects ahead of customer and scheduling expectations. Designed experiments, developed test plans, coordinated lab activities (sub-scale & full-scale) including final test reports and technical presentations for ATK and NASA senior technical and program management. Organized and led numerous PFEMA's, product, facility and tooling design reviews and Operation Readiness Implementation (ORI) teams. Defined and coordinated all sub-scale R & D lab testing and full-scale qualification testing/checkout at vendor before shipment and production facility through final installation, qualification and first article inspection. Manufacturing planning engineer developing processes, identifying resources (bills of material, facilities, tooling, support documentation) and writing technical planning instructions from new and improved design blueprints and specifications for most space shuttle RSRM nozzle bond and assembly manufacturing processes. Production line support engineer resolving manufacturing issues with root cause analysis, 100% corrective action implementation, defining discrepant hardware, facility and tooling dispositions, obtaining Material Review Board (MRB) customer approval and expediting implementation of associated r...
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