Matthew B. McCoy

**** **** ****** **.

Lexington, NC 27292

Cell 513-***-****

Email: acga2a@r.postjobfree.com

WORK HISTORY

Turkish Aerospace Inc., Ankara Turkey

Lean Consulting Engineer

December 2013 to July 2014

As a Contract Consultant, I was responsible for driving lean processes and tools that provide

sustaining change in the customer organization. Help establish teams to take ownership of new

processes developed for implementing a lean culture into the organization, and drive the

sustaining change throughout their areas.

General Electric Aviation, Evandale, Oh.

Sr. Lead Manufacturing Engineer

Design Manual, and Automation Lines for Robotic Welding, Assembly, & Painting, De-

Burring and Inspection

May 2011 to December 2013

Responsible for design of lean cells, stations and tooling for them. Process, timing and

sequence of operations for new manual, and automated production to improve first time yield,

cost reductions and throughput. Lead ad-hoc teams in different manufacturing facilities to drive

lean processes, automation, robot programming, and integration. Introduction of state of the art

automation for close tolerance robotic hole drilling and rivet applications. Introduced the use of

Laser Trackers for robot positioning and quality reports for true position tolerances. Savings of

45 hours per assembly obtained from this new automation cell.

I design of a complete automated paint line for a new facility in Mississippi. Included in the

design are power & free conveyor systems, lean parts flow and limited material handling.

Develop SOW and Buy Specifications, vendor selection, support, and integration.

Application submitted for patent of a new robotic assembly process. The patent application was

submitted in February of 2012, ten months after being employed by GE Aviation.

Authored a handbook entitled “Transition to Production.” The manual defined how to prove

tooling will support the lean manufacturing production process before Start of Production (SOP,)

and begin implementing 5S, Six Sigma, and continuous quality improvement immediately.

BAE Systems, Fairfield, Oh.

Sr. Lead Manufacturing Engineer

Design Production Lines for Government and Armored Vehicles, Process Development

February 2009 to May 2011

Responsible for launch of new programs, creating new and optimizing existing production

processes for cost reduction and improved quality. I was also responsible for 18 manufacturing

engineers, 2 robot programmers, and a 325,000 sq. ft. manufacturing facility.

Implemented standardized launch criteria for new programs that included manufacturing and

quality plans. Drive lean Manufacturing Principals, Kaizen Events, 5S, and comprehensive PM

(preventative maintenance) schedules for tooling and fixtures to begin at program start-up.

Planned with maintenance to order and maintain spare tool & fixture parts to limit production

downtime. Provided ME’s with a Continuous Quality Improvement atmosphere that focuses on

process improvement, and cost reduction throughout the life of the program. Quoting and

business case development for CAPEX expenditures to support new program launches, capital

equipment, and production start up costs. Creation of an Excel spreadsheet to record

standardized work times, sequence of operations and timing. IPT Team reviews of Product

Designs for DFM, and DFA, Tool Designs, and Quality Plans to ensure adherence to PPAP,

DFMEA, PFMEA, guidelines and requirements. I introduced use of a new Laser Tracker for

inspection, set-up of production tooling, and tool calibration.

Designed and implemented fully automated robotic weld cells to mig weld BIW armored truck

cabs. These process improvements led to a productivity increase that reduced build time by 35

hours per unit for 4400 total units.

Worked with product engineering groups to redesign armored cab panels and reduced number

of panels from 10 panels to 5 panels. The redesign also saw a reduction of 2000 inches of mig

weld, and resulted in a cost savings of $589.00 per unit for 4500 cabs.

I created program files with samples and templates to standardize Manufacturing Engineering

Program data for use on the shop floor. Also set-up mandatory training classes on the BAE L&D

Training Network. This is used to provide continuous educational improvement for the

employees, while making them a more valuable asset to the company.

Edag Productions LLC, Auburn Hills, Mi.

Engineering Manager

Tomcar Off-road Vehicle Line, Supplier Development, Product Development, New

Program Launch, and Business Development

August 2003 to January 2009

Responsible for quoting and business case development for new product designs, launches,

manufacturing process, production line designs, and timing through put. Designed and

implemented production line to build complete Tomcar Off Road Side x Side vehicle. I worked

with suppliers in USA to manufacture a newly designed wiring harness, MIG welded frames (3)

styles, and other complex vehicle components for high quality with competitive pricing. Working

extensively with suppliers in Taiwan, China, and the USA to supply parts and assemblies of high

quality and low price. The following new products included front and rear coil over shocks,

aluminum three and four core radiators, a complete exhaust system with catalytic converter, a

new rack and pinion assembly, aluminum wheels, steel gas tanks, and miscellaneous machined

components. Cost saving benefits of $20 million dollars over a five year period achieved

utilizing Asian suppliers. Set-up spare part program, and warranty programs with all overseas,

and U.S. suppliers. I provided engineering support and direction for EPA certification programs,

also various water, air quality, and hazardous waste disposal compliance testing and government,

state, or city permits. Product & tooling design reviews, also working with quality engineers to

support PPAP, and DFMEA requirements. Managed up to 45 employees in different disciplines.

J.S. McNamara Inc. Warren, Mi.

Catia Design Supervisor

Metal Forming Equipment, Rivet & Weld Lines, Pierce Stations, Jig & Fixture, Special

Machines, and Material Handling Equipment

June 1997 to July 2003

Responsible for tool content, budgets, schedule, and progress. I was also lead for 25 to 28 Catia

design engineers. Concept, design, layout, and detailing of automotive rollform & hemmer

equipment and presses, robot end effectors, transfer equipment, heavy truck rivet cells, body side

& under body weld systems, under body pierce stations, fixture and special machine design.

Program kickoff, setup & conducting formal customer design reviews, & change management.

Follow up with customer and build shops to ensure cost, timing, and quality are met as required.

All work in SolidE or advanced surfacing to Chrysler, GM and Freightliner modeling and design

standards.

Odyssey Inc. Oxford Mi.

Catia Design Supervisor & Catia Data Manager

Boeing 737-700 Program, Alcoa / Chrysler Prowler Program

April 1995 to June 1997

Design Supervisor of (7) Catia Design Engineers

Responsible for tool content, budgets, schedule, progress. Also lead 7 Catia design engineers,

and 3 N/C programmers. Concept, design, layout, and detail of weld fixtures, drill & assembly

jigs, N/C mill fixtures, special machines, and bond tools. Formal customer design reviews,

change management, and follow up with customer and build shops. All work in SolidE or

advanced surfacing to customer modeling and design standards.

Saturn, Troy, Mi.

Consultant: Catia; Standards & Process Development in a Manufacturing Environment.

Saturn Car Co.

Phoenix 2000 Program

Feb. 1995 to Oct. 1995

Catia Applications Development

Responsible for developing and documenting Catia modeling standards, processes, and design

requirements for the Metal Stamping, Polymer, and Assembly Manufacturing Engineering

groups. Compiled training requirements and implemented a Catia Training Program for

instituting DFM, DFA, PFMEA and DFMEA in a 3D Cad environment.

Modern Engineering Inc. Troy, Mi .

Senior Lead Catia Design Engineer.

USAF F-22 Fighter Program.

Aug. 1994 to Feb. 1995

Senior Design Lead of (10) Catia design engineers

Responsible for designing and directing team of ten tool design engineers from concept

through production of invar steel bond tools for carbon epoxy production parts, and five axis

milling fixtures. All work in solids and advanced surfacing.

M & T Design Services Inc. Madison Hts, Mi.

Senior Lead Design Engineer

Oct.1992 to Aug.1994

Product Designer

Design of chassis components for Chrysler programs to include shock towers,

trailing arm assemblies, cross member supports, etc. All designs utilized Catia advanced

surfacing, wireframe, and draw for prototype release to production.

Senior Design Lead FSX Fighter Program of bond tooling for carbon epoxy parts.

Internal Product Team member at Boeing for 777 Strut & Nacelle tooling program.

Responsible for designing and directing team of (5) tool design engineers for large assembly jigs,

large bond tools for carbon epoxy parts, and final assembly trim tools utilizing Catia solids,

advanced surfacing and draw to produce drawings for full production release. Tool fabrication

shop support for fabrication, quality, and cost reduction solutions. All work in solids and

advanced surfacing.

Boeing Commercial Aircraft, Seattle Wa.

Senior Project Manager

May 1991 to Oct.1992

Senior Project Manager, Tool Design Offload

Responsible for directing and coordinating supplier tooling from concept and design to

quality concerns from production. Also responsible for conducting tooling and manufacturing

surveys, directing/monitoring the design build process for improvements to scheduling and cost

reduction. Tooling types included floor assembly jigs, scaffolding and material handling

equipment. All work in solids and advanced surfacing.

McDonnell Douglas Aircraft Co., St. Louis, Mo.

Tool Design Engineer, Fabrication Representative to Tooling Suppliers

Sept.1987 to Jan. 1991

Tooling Design and Fabrication Representative

Responsible for directing and coordinating supplier tool designs, tool manufacturing, and

quality from concept through production tryout. Also budget, delivery, and program status. All

work in advanced surfacing and wireframe. Worked AV-8B Harrier, YF-23, A-12, C-17, and F-

22 composite tooling. Secret security clearance.

EDUCATION

Tool Designer and Tool and Die Maker: Served (4) year apprenticeship for jig & fixtures, and (2)

year tool & die apprenticeship.

Drafting for Machine Shop, Machine Shop Practices, Blue Print Interpretation

North County Technical School

Masters Certificate in Management and Leadership

BS Engineering Technology

Currently working on my BA in Business Management

Certificate in Jet Engine Teardown School, GE Aviation

Six Sigma Green Belt

Fanuc Robot Programming – classes in beginning & advanced robot programming

62 Continuing Education Credits through Defense Acquisition University

21 hours Continuing Education BAE Learning Center

72 hours Continuing Education GE Aviation Learning Center

Certificates for courses in Continuous Quality Improvement, Project Management, and Catia.

Cad 2D & 3D Design, Surfacing, Advanced Surfacing, Solids, N/C Programming, Tool Design,

and Designing for Composites.

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