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Maintenance Engineer

Location:
Mississauga, Ontario, L5M 7G1, Canada
Salary:
negotiable
Posted:
May 07, 2012
Email:
hi7nql@r.postjobfree.com
Contact Info:
*************@*******.***


yakout shalaby - Profile
**** ******* ******, ***********, *******, Canada L5M 7G1
905-***-**** / 912-***-****
hi7nql@r.postjobfree.com, hi7nql@r.postjobfree.com

“Yakout, this week has given! us a couple of AOG incidents on the SAS Q400 (tail strike on 4018 and pulled out lavatory fitting on 4008) which has lead to some opportunity to use the structural ID section of the S400 SRM. For both situations the ID proved to be extremely useful and accurate. The completeness of the ID actually prompted compliments from the FSR on site at SAS airlines when he used it to create the initial damage report for en - the tail strike and we also used it for the subsequent on-site damage survey by our engineer. Today we again used it to quickly identify part numbers for the damage to the lavatory service structure and were very pleasantly surprised by it's accuracy and completeness. I just wanted to let you know that the long hours you spent on these sections (some parts in their entirety, others requiring much time to verify and patch up partner data) is paying off in making the manual useful. Thanks, Maurice Clark, Chief, In-Service Structures Engineering”

“Resolved Bombardier aircraft manufacturer and airlines/customers hard problems when main engine-driven hydraulic pumps failed at about 1000 flight hours on new product Q400 turboprop 78 seats by authoring accurate and practical maintenance procedures to dispatch grounded aircraft by flushing hydraulic systems, cleaning all trapped metal debris from hydraulic systems components and replacing defective malfunctioned pumps to return aircraft to service in a timely fashion”

Slashed manufacturing time to save 56.60% with 50% manpower building global express XRS and 5000 rear fuselage:
“Motivating my team, successfully saved 56.60% of the manufacturing time of final assembly, fabricating Global Express and Global 5000 rear fuselage when accelerated the loading cycle of Rear Fuselage from 9 days down to 4 days, applying and utilizing FAA.EASA/TC [Transport Canada]/FARs/JARs/CARs/ATA-100/2200 standards/regulations and lean manufacturing methodology/philosophy along with six sigma blitzes for continuous improvement/risk management control and plan accelerated the whole final assembly lines movement and integration operations production plan. With the demand of increasing productivity with reducing cost of production, managed to reduce headcount of crew by 50% (30 out of 60) to 30 personnel and team still committed to delivering 100% outcome on time with best quality to exceed customer expectations.”
Qualification Summary:
20 years plus experience in aerospace engineering. Work productively and efficiently while being able to adjust to multiple tasks demands. Skills are easily adaptable to other disciplines requiring my technical and analytical skills. Experience in hydraulics, pneumatics, flight controls and fuel systems, adaptable analytical skills, highly motivated, decisive and results-oriented individual with ability to analyze information and evaluate results to choose the best solution and solve problems for continuous improvement with practical application of lean six sigma analysis for continuous improvement, dedicated to achievement and success for my employer to exceed customers’ expectations. Deep and accurate knowledge of MSG-3 analysis and of CARs/FARs/JARs Part 25 and Parts 23, 27, 29 , 33, aircraft mishap analysis, maintenance (preventive/predictive/corrective, scheduled or MRB maintenance. achieved and maintained for customers airlines lower cost of operation as 30 minutes per aircraft to return to service RTS tasks to remove/install line replaceable unit LRU or performing operational/functional tests.
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EDUCATION & PROFESSIONAL DEVELOPMENT
Ontario Aerospace Council (OAC): Aerospace Manufacturing Certificate, Humber College/North Campus, Etobicoke, Ontario– Student Number: 801-737-289
AutoCAD Technology Program –Durham College, Whitby, Ontario.
Certificate microcomputers – Faculty of Engineering, University of Alexandria, Egypt.
Statistical methods to establish and budget air force task forces-National Institute of Statistics-Cairo, Egypt.
5-year B.SC. Aeronautics GPA 4 [very good evaluation] -The Military Technical College, Cairo, Egypt-Evaluated/recognized by University of Toronto and university of New York City.

PROFESSIONAL LICENSE:
Syndicate of Engineers – 30 Ramsis Street, Cairo – Egypt – P: 011-02-574-7479 / 80 / 81 / 82 – F: 011-02-574-8634 / 011-02-575-0501, hi7nql@r.postjobfree.com, License number: 6920/9 – Section: Mechanical engineering – aeronautics.

DEVELOPMENT COURSES:
2010: Honeywell Turbo Fan engine HTF7000 Module – Flight safety, Gulfstream, Savannah, GA31408, USA
2009: Supply Chain SC - Canadian Standards Association CSA / Canadian Supply Chain Sector Council CSCSC,
2009: Lean Manufacturing LM, DBM, 77 City Center Drive, East Tower, Suite 401, Mississauga, ON L5B 1M5:
2009: Project Management PM: DBM, 77 City Center Drive, East Tower, Suite 401, Mississauga, ON L5B 1M5:
2007: Leadership In Action: Conducted by Bombardier: Art of leading personnel to achieve defined goals.
2006: Leadership Engagement Forum: Bombardier:.
2005: Six sigma Analyst/Agent: Statistical Process control to improve quality, delivery and cost-Bombardier Aerospace
2004: Liability, MSG-3, Maintenance planning/programming - Bombardier Aerospace
2000: D8-Series Q100/200/300/400, operation/maintenance of Systems/Powerplant/structure - FlightSafety Canada, Toronto
2000 Introduction to Supervision -: American Management Association AMA – Bombardier
2000: Advanced Composite Aircraft Structures, AbarisTraining Center: Reno, Nevada:
Advanced Composite Structures: Fabrication and Damage Repair Phase I/Transport Canada Approval No.TC-708-91-02. Advanced Composite Structures Phase II/Transport Canada Approval No.TC-709-91-02.
1999: Avionics/communications/navigation - Bombardier Aerospace, Toronto, Ontario,
1998: Canadian/American/European Aviation Regulations aerospace standards FAA.EASA/TC [Transport Canada]/FARs/ JARs/CARs/ATA-100/2200 standards and regulations focused on CAR/FAR/JAR chapter - 25 .
1998: Six Sigma to minimize all variance and maximize efficiency and productivity with continuous improvement.
1997: Life*CDM: Arbor Text’s ADEPT*Editor to use SGML for ETPS-Bombardier Aerospace: CRI and Arbor Text
1980-1981: USAF military aircraft maintenance chief engineer training in Lackland-AFB, TX, Ft Worth Dallas-AFB-TX, General Dynamics, Hill – AFB-UT and Pratt & Whitney, Miami, FL for F-16 Program (peace vector - program): as air wing maintenance chief.
1970-1985: Accomplished all fundamental engineering, technical and military regulatory training, Combat operations readiness / maintenance/ repair/overhaul/reliability/modifications and parts logistics for maintenance programs/planning for fleet of fighters MIG-21/23 all series, SU-7/17, F-16.

ACHIEVEMENTS AND ACCOMPLISHMENTS:
* Dedicated and committed to achievement, completed my project of work for gulfstream six month ahead of time.
*Successfully saved 56.60% of the manufacturing time fabricating Global Express/Global 5000 rear fuselage when accelerated the loading cycle of Rear Fuselage to 4 days down from 9 days.
* Resolved Bombardier aircraft manufacturer and airlines/customers hard problems when main engine-driven hydraulic pumps failed at about 1000 flight hours on new product Q400 turboprop 78 seats by authoring accurate and practical maintenance procedures to dispatch grounded aircraft by flushing hydraulic systems, cleaning all trapped metal debris from hydraulic systems components and replacing defective malfunctioned pumps to return aircraft to service in a timely fashion.

*Shared in achieving and making commercial aircraft Q400 turboprop 78-seat best seller with low and controlled maintenance/operation cost.
*Created an efficient flight test program for delta wing supersonic aircraft. The undertakings became flight test standard procedure.
*Improved Aircraft performance by: 1 - Designed a WOW sensor microswitch to energize a solenoid valve to relieve the excess pressure in the hydraulic reservoir. The idea used later to de-energize and secure the two machine guns on the ground.
*Improved and modified performance of Boundary Layer Control System on a supersonic delta wing
*Devised a structural repair solution to compensate wear and wing play.
*Constructed a pneumatic/hydraulic [pneudraulic and electro-mech-draulic components] components test stand [rig] and jet engine test-stand facilities for verifications of engines' specifications/engine's performance analysis/
* Invented a new spare parts stock system based on supply chain management, called “SCALER – Spares Calculated (Against) Airlines Economized Request”
*Achieved practical application in the design, development and publication of electromechanical curriculum, handouts, OJT with skill-measure exams for Raytheon/Air Defense Institute.
*Authored the first accurate/practical/validated Structural Repair Manual SRM for D8-Series 400
Work Experience:
October 2010 – Present : Maintenance Program Development Lead Engineer, iAccess Technologies, 5000 E. Spring St. Suite #385, Long Beach, CA 90815, Long Beach, CA & Nagoya, Southern Japan – Mitsubishi Aircraft Corp, 90-Seat Mitsubishi Regional Jet - MRJ-200STD/ ER/LR : FAA MSG-3 maintenance program philosophy for Avionics, Hydraulics, Fuel Systems, Flight Controls, fuel system, landing gear, ATA25 equipment and furnishings, I have completed all MSG-3 analysis for MRB tasks for ATA 25 for new Mitsubishi regional aircraft MRJ-200 for: Flight deck / compartment, pilot and co-pilot seats, observer seat, Flight deck door , FWD and AFT flight attendant seat, passenger seat - economy class, passenger seat - premium class, FWD and AFT Galley, emergency escape slide, life rafts, Fixed emergency locator transmitter ELT, Survival type ELT, overhead bin, passenger service unit PSU, in-flight entertainment IFE, Cargo compartment, Acoustic and thermal interior insulation [protection against heat and sound] for flight compartment, passenger compartment, cargo and accessory compartment. Fire protection, autopilot, Power Plant and Structures for MRB tasks for all ATA chapters. Professionally represent the company while supporting the customer with aircraft maintenance analysis, reviews, and presentations. Aircraft reliability experience with aircraft maintenance experience. lead a team of engineers in the development of aircraft maintenance programs by working with product development teams, WG, FAA, and analyzing MSI component and systems performance in terms of reliability, maintainability, and system safety FHA, Relex Reliability Prediction to determine maintenance task intervals. Lead a group of engineer, train Japanese engineers in Nagoya. Complete MSG-3 analysis using reliability data [Mean Time Between Unscheduled Removal] (MTBUR), [Mean Time Between Failure] (MTBF) and [Failure mode data and Failure Mode Effect Analysis] (FMEA). Provide training and feedback on maintenance program analysis by OEM customer. Present completed technical analysis to a diverse and highly competent team of airline and regulatory personnel during Working Groups (WG) meetings and Industry Steering Committee (ISC) meetings. Type certification TC based on airworthiness inspection manual AIM and continuous airworthiness 14 CFR part 25 Appendix H. Maintain detailed program record, including customer and airline meetings. Coordinate with technical publications group to ensure requirements and tasks are included in aircraft manuals. , maintenance (preventive/predictive/corrective). Coordinate with Flight Operations on maintenance requirements. Experience with Microsoft Office suite and aircraft manuals.

Jan-2010 – September - 2011: Senior technical writer, Functional test, operational test, MRB fault fining tasks, MSG-3 – return to service RTS, – Gulfstream Aerospace - General Dynamics, 500 Gulfstream Road, 800-810-GULF[4853], Savannah, GA 31408-USA: Customer service – aircraft maintenance documentations, qualification test reports/procedures QTP, acceptance test reports/procedures ATP, flow chart/diagram, validating and testing maintenance and return aircraft to service procedures RTS, and functional test and operational test procedures along with visual and detailed inspection/check as fault finding tasks for Aircraft G250 AMM ATA- all chapters and ELMM, EHMM, SRM, FIM, CMM, System Description Section SDS for gulfstream flight safety international and Engine Light Maintenance Manual LMM for Honeywell Turbo Fan Engine IPPS model AS907-2-1G [HTFT7000] Integrated Powerplant System, airborne auxiliary power unit and APU model 36-150, Spirit fuel system, intertechnique fuel system , achieve high maintenance cost control to reduce cost of operations of aircraft, maintained lower cost of operation as 30 minutes per aircraft to return to service RTS task to remove/install line replaceable unit LRU or performing operational/functional tests. Managed to correct fuel system [similar to Airbus fuel system] and insure installation of fuel probes require insulation with minimum 100 Mega ohms not bonding with zero or 2.50 mille ohms to avoid arcing or potential of fire in fuel tanks. Excellent understanding and knowledge of MSG-3, MRB, maintenance planning/programming along with performance failure mode effect/failure tree/function Hazard analysis (FMEA/FTA/FHA), reliability, maintainability and safety. Gulfstream aerospace standards and software: MIL, MS, ATA-100, ATA-2200 , Content@, Arbortext Editor, SGML, SmarTeam, Right Hemisphere, Lotus Notes 8, VisView, SmarTeam, KeyID Database, Hprsnap6, PLM Dashboard, Teamcenter visualization professional SR 1 - life cycle UGS, Deep Exploration, Microsoft Office [Excel, Word, PowerPoint], Adobe Acrobat [with Edit Tools], Live Link Explorer, TechIllus, Convert tool, PdocM, Beacon3 Folder, P30 Project on Livelink, P30RHTemp on savrhapp2, Mantra – 3D CATIA VIEWS, prj030_wk [product data management system with TEAMCENTER UGS 2005 lifecycle visualization to view graphics and CATIA files], Deep Access, CMP.net [Legacy], SmartTeam, Spreadsheets, G250 Accessibility PDF, G250 Status excel sheet, reliability software Windchill Prediction (Relex Reliability Prediction)

Jan-2005- April-2009: Operations Line Manager – Global Express XRS/Global 5000 (Business Aircraft) Final Assembly Tracking System FATS- Bombardier Aerospace: In depth knowledge and experience in budgeting control, manufacturing, scheduling, FAA.EASA/TC [Transport Canada]/FARs/JARs/CARs/ATA-100/2200 standards with adherence to quality, cost and delivery and plan/implement/ control functions activities. Coach/develop/provide feedback to employees and address their issues. Utilize six sigma/lean methodology for best practice in quality and cost for deliverables by minimizing number of quality reports of non-conformance RNCs. Continuous improvement/risk management control and plan to eliminate waste in everything we do, Maintain housekeeping standard to ensure a safe working environment. Continuous improvement-lean practice. successfully saved 56.60% of the manufacturing time of final assembly with 50% manpower, fabricating global express / global 5000 rear fuselage when accelerated the loading and building cycle of Rear Fuselage in 4 days down from 9 days, applying lean manufacturing methodology/ philosophy along with six sigma blitz for continuous improvement/risk management control. With the demand of increasing productivity with reducing cost of production, managed to trim crew by 50% (30 out of 60) and still committed to delivering 100% outcome.

Nov-1997-Jan-2005: Computerized maintenance program CMP, Functional test, operational test, MRB fault fining tasks, MSG-3 - Senior tech writer - Bombardier Aerospace – Electronic Technical Publications Systems [ETPS] - Toronto, Ontario: Authoring/validating/testing aircraft maintenance manual (removal/installation/operational test /functional test/ return aircraft to service procedures/standard maintenance practices)/component maintenance/fault isolation manuals by SGML/Adept Editor/AMTOSS and simplified English SE for flight controls/fuel/hydraulics systems, standard maintenance practices, structural repair manual, achieved and maintained for customers airlines lower cost of operation as 30 minutes per aircraft to return to service RTS task to remove/install line replaceable unit LRU or performing operational/functional tests. MRB/CMR/MPD program. All ATA Chapters, applicable aerospace standards FAA/EASA/TC [Transport Canada]/FARs/EASA/CARs/ATA-100/2200 standards and regulations/Airworthiness Requirements/CARs/FARs/EASA. SGML as per ATA-100/2200 requirements. Product/customer support by initiating flush procedures for hydraulic rotary components/pumps failure. Works professionally under pressure of deadlines and airlines urgent maintenance needs. Knowledge of MSG-3, MRB, maintenance planning/programming along with performance failure mode effect/failure tree/function Hazard analysis (FMEA/FTA/FHA), reliability, maintainability and safety., reliability software Windchill Prediction (Relex Reliability Prediction)
1990-Present: Math/Physics Tutoring (P/T): Hi school to College/University level – physics/math/Calculus/finite/algebra/ trigonometry and plane and solid geometry/finance math/mathematical analysis and modules for business, finance institutions, industry and economic applications along with American college/university entrance exam SAT (scholastic aptitude test), GED (general education diploma), ACT (American college test), GRE (Graduate record exam). Long term experience tutoring with excellent command of math and physics for high schools/college/university levels measured by my students’ high marks in all exams.
Feb-1987-July-1994 - Raytheon, Air Defense Institute - Jeddah, Saudi Arabia – Senior Technical Instructor/lecturer: Responsibilities included: performing a variety of engineering work in designing, constructing, and testing aircraft, missiles, and spacecraft. tech and engineering with best caliber curriculum specialist authoring/writing/revising/validating and testing new training manuals and materials in field/hand-outs/practical lab plans and analysis – established electromechanical labs – Authored pre-requisite exams/graduation final exams/monthly tests/quizzes - graduated qualified air defense/missiles officers, non-commissioned officers to operate and maintain sophisticated Air Defense Hawk missiles command and control systems and ground equipment, with OJT programs for engineers and technicians follow up in the field to qualify for higher level promotion.
Feb-1985-Jan-1987 - Multi-trade Training Center Director-General, Alexandria, Egypt Government, funded by UN International Labor Organization. Large size training center for construction, building and maintenance trades skills.
05-1970 to 01-1985: Egypt air force bases, nationwide:
01-1979 to 01-1985: Air force Chief of Maintenance planning/program Engineer for three remote air force bases
01-1975 to 01-1979: Airworthiness, reliability, maintainability and safety,
05-1970 to 01-1975: In-service and systems engineer
Author service and repair and mods procedures for fuel, hydraulics and flight controls systems, powerplant, troubleshooting of systems, powerplant, avionics and electrical systems of jet engine and turbo prop aircraft.. Inspection of aircraft and engines. Perform line maintenance, MRB tasks. Reliability Analysis Program (RAP 95-1), reliability software Windchill Prediction (Relex Reliability Prediction). General Procedures Manual. Alternate Methods of Compliance (AMOCs) for repairs, alterations, and modifications. Evaluate Federal Aviation Regulations (FARs), Notices of Proposed Rulemaking (NPRMs), Airworthiness Directives (ADs), Service Bulletins (SBs), Service Letters (SLs), and other notifications of in-service issues. FEMA, FMECA, FTA, fail safe design, risk assessment, Evaluate Federal Aviation Regulations (FARs). Accomplish service bulletins for modifications, and airworthy directives as applicable and required. Good working knowledge of AMM, AIPC, SRM, FIM, CMM, ITEM & phase card system for commercial/ military aircraft and assist in training. Served Egyptian air force bases, nationwide for 300 aircraft fleet in three air force bases in decentralized commandership. MSG-3, MRB, airworthiness rules, standard and functions for technical airworthiness authorities TAA, engineering control manual ECM. Reverse engineering for aircraft parts and structures.
in-service engineering and on site technical assistance, configuration management CM for integrity, traceability and continuity of technical decisions, quality continuous improvement for customer satisfaction with leadership quality to lead, coach and train, maintenance planning/programming along with performance failure mode effect/failure tree/function Hazard for analysis (FMEA/FTA/FHA), reliability, maintainability and safety. Russian aircraft maintenance SU-7, SU-17. MIG-21M, MIG-21MF, MIG-23, Chopper Mi-6 and Mi-8 and 100 American aircraft F-16. Responsibilities included: performing engineering work in assembling, repairing, overhauling and testing aircraft and aerospace ground equipment AGE.

*Reverse engineering experience to cover for shortage of parts for air force fighter-bomber aircraft, specially for high pressure hydraulic hoses and hydraulic fittings certified by destructive tests with hose failure or fracture at 9000 psi [it is 7500 psi in USA], fabrication of hydraulic high pressure stainless steel and titanium tubes, pneumatic and fuel lines, AC and DC cooling elbows and air ducts when got cracked on aged fighters , sheet metal / structure parts fabrication of any geometric shapes, shared in increasing operational battle range for fighter MIG-21 by fabricating and installing 1000-liter belly tank under mid fuselage, modified later to oval cross section not circular to avoid tank strike with runway. Secured aircraft SU-7 machine guns from firing while aircraft is on ground by adding normally opened NO micro switch similar to WOW switch to open the firing circuit on ground.
* writing technical reports and other documentation, such as trainee/students handbooks and bulletins.
* Experience and working knowledge of FAR CHPTER 25, FAR Part 91 and 135 Operations and Experience with FAR Part 121 and FAR Part 135 Operations.
* Experience in managing Repair Station and the associated processes.
* Ability to work in a fast paced team multi-task environment and maintain high degree of high quality professional outcome.