Engineer Manufacturing

GARY N. CARLSEN

*** ********* *****

Milledgeville, GA 31061

Cell 478-***-****

Email: ********@*****.***

Summary:

Manufacturing, Industrial and Quality Engineer with over twenty years experience, including

aircraft, automobile, bus & rail car. Experience ranging from detail parts fabrication through

final assembly of commercial & military aircraft, including JIT, APICS / MRP. ISO 9000-9003

qualified. Expertise in composite materials processing & handling. Experienced in cast &

machined parts, sheet metal forming, heat treatment, and finishing. Experience using Catia V 4,

and V5, CAD-AM & CADRA design systems, and Enovia and SAP systems. Possess a working

knowledge of Microsoft Office with a strong emphasis in the application of Microsoft Excel and

Microsoft Word. Experience in all phases associated with metal bonding. Knowledgeable in

chemical milling processes, and experience working with compression and injection molding.

I hold a DOD security clearance at the SECRET level.

My extensive work history in the aerospace field with a strong emphasis in composites is

reflected in the following.

Experience:

GKN Aerospace,Hazelwood Mo.

Senior Production Engineer 01/2012 to 12/ 2012

Liason/ MRB Engineer supporting Sikorsky Helicopter CH53K program. Dispositioning discrepancies

to composite bonded assemblies and aft structure assembly. Performed cause and corrective action

investigations.

Liason/ MRB Engineer supporting Northrop/Grumman E2-D Aluminum Honeycomb Bonded Assembly manufacturing

program. Supported production work order updates, Tooling remanufacture and corrections as needed. Performed

Cause and corrective action investigations

Morgan/ A.Stanley Company, Huntsville Al

.Weststar Aerospace & Defense Group Huntsville Al.

Senior Materials Engineer 02/ 2009 to 3/ 2011.

Supporting the U.S. Army Aviation Engineering Directorate at Redstone Arsenal, Huntsville

Alabama in reviewing and evaluating various contractor documents and test plans including

those for Materials Characterization, Fatigue Testing, First Article Inspection, Source Approval

Requests, Airworthiness Qualification Plans, Failure Analysis, and Quality Deficiency Reports.

Review and analysis of Helicopter and Fixed Wing System/ Sub System Composite and Non

Metals Material Designs to determine whether Airworthiness has been maintained with the

design.

Attendance at Contractor Design Reviews to oversee the overall design compliance with

airworthiness requirements. Travel to manufacturing facilities to ensure composite material parts

are being properly fabricated.

Review Field Damage to Non Metal Aircraft Parts and recommend repair procedures that ensure

airworthiness of the item is maintained.

Sikorsky Helicopter, Stratford Ct.

Senior Materials Engineer 12/04 to 03/08.

Responsible for maintaining work instruction and tooling current to latest engineering

requirement on main rotor blades (S92-A/ UH60-M Aircraft. Senior Liaison Engineer.

(Composites) Disposition writing for main rotor blade repairs. MRB and standard repair.

Writing corrective action tags. Senior Materials and Process Engineer. Developing Autoclave

(BCC) Cure cycles. Investigating new and alternate materials. Developing alternate

manufacturing processes. Expertise in the design, development, and review of advanced

composite material for commercial structures. Knowledgable with the most recent

technologies, principles and methods in the industry. Conducted various tests and analyzed

results. Provide results and advice for numerous clients in the respective field. Ability to

resolve structural design discrepancies. Provides leadership and insight to less experienced

engineers and designers.

General Dynamics Armament and Technical Products, Glen Cove, NY

Senior Manufacturing Engineer 10/03 to 10/04.

Responsible for analyzing process documentation and tooling for transfer to other company

facilities. Shop floor manufacturing support. Expertise in the design, development, and review

of advanced composite material for commercial structures. Conducted various tests and

analyzed results of graphite epoxy and other composite materials. Provide results and

advice for numerous clients in the respective field. Ability to resolve structural design

discrepancies. Provides leadership and insight to less experienced engineers and designers.

Pratt and Whitney, Hartford, CT

Senior Materials Engineer 8/01 to 10/03

Addressing production issues in the manufacture of materials, which can sustain high

temperatures (titanium, nickel, and alloys). Maintained and revised process work instruction

utilizing the CAPP 2 document system. Expertise includes the knowledge of advanced

engineering methods and principles as well as knowledge of industry related tools and

software.

Delta Airlines, Atlanta, GA

Senior Materials and Process Engineer 10/00 to 7/01

Analyzed process documents to assure compliance to FAA part 145 requirements. Expertise in

the design, development, and review of advanced composite material for commercial

structures. Conducted various tests and analyzed results. Provide results and advise for

numerous clients in the respective field. Ability to resolve structural design discrepancies.

Provides leadership and insight to less experienced engineers and designers.

Sikorsky Helicopter, Stratford, CT

Senior Manufacturing Engineer 11/99 to 10/00

Major/ Final Assembly Cognizant Engineer. Investigated and resolved interference and fit issues.

Initiated and implemented tooling and shop work instruction changes as required. Revised and

corrected process work instruction utilizing the CAPP 2 document system.

Timco, Greensboro, NC & Macon, GA

Senior Engineer 2/99 to 4/99

Analyzed and corrected defects found during aircraft "C" and "D" checks, also passenger to

freighter mod. Aircraft DC-8, DC-9/MD80 series, B-727, 737, and 767. Writing dispositions

and corrective action tags. Minor - SRM repairs Major - DER-8110-3 approvals.

VisionAire, Corp. St. Louis, MO

Engineering Manager / Senior Engineer, MRB 5/98 to 1/99

On-site representative of VisionAire Corp, at fuselage manufacturing facility in Clearwater, FL.

Responsible for coordination of design efforts, tooling & planning to produce industry first

composite, single engine business jet. Approved drawings, specifications, processes & vendors

related to program. Responsible for all on-site MRB activity.

Lockheed / Martin, Baltimore, MD

Sr. Industrial Engineer 3/97 to 5/98

Responsible for scheduling, Assembly Floor layout & tooling studies. Selected & authorized

purchase of floor support inventory. Evaluated employee suggestions.

Boeing Commercial Aircraft Co, Wichita, KS

Sr. Manufacturing Engineer 2/96 to 2/97

Responsible for analysis and conversion of existing aircraft planning into new company-wide

computer system (DCAC / MRM).

Thrall Rail Car, Cartersville, GA

Sr. Industrial Engineer (Contract) 9/95 to 2/ 96

Responsible for time studies, crew loading studies. Conceived, initiated & implemented

improvements in company procedures & processes. Identified & corrected tooling errors.

Dispositioned manufacturing discrepancies. Wrote corrective action documentation.

Sikorsky Helicopter Co, Stratford, CT

Sr. Manufacturing Engineer (Contract) 4/94 to 3/95

Evaluated & resolved composite manufacturing problems. Responsible for analysis & correction

of composite tooling discrepancies. Revised and corrected shop work instruction utilizing the

CAPP 2 System.

Sikorsky Helicopter Co, Stratford, CT

Sr. Manufacturing / Quality Engineer (Contract) 10/92 to 12/93

Supplier Liaison Representative. Qualified program Suppliers. Performed root cause analysis &

resolved discrepancies involving castings, forgings, machined & sheet metal parts, chemical

processes & composites.

Grumman Aerospace Co, Melbourne, FL

Sr. Manufacturing Engineer (Contract) 4/91 to 12/91

Anticipated & planned structural modifications to Boeing 707 for "J-STARS" conversion.

Sr. Liaison Engineer, MRB

Reviewed, analyzed & dispositioned discrepancies arising during J-STARS conversion.

Extensive experience with both composite & metallic details & assemblies. Wrote corrective

action documentation. (MRB and standard repair).

Grumman Aerospace Co, Calverton, NY

Sr. Manufacturing / Quality Engineer 3/90 to 10/90

Cognizant flight test Engineer. Performed investigations of & corrected manufacturing

discrepancies. Analyzed & resolved flight crabs (air crew complaints). Gathered & Maintained

SPC data for continuous quality improvement purposes.

Grumman Aerospace Co, Bethpage, NY

Sr. Manufacturing / Quality Engineer 6/84 to 3/90

Cognizant flight test Engineer. Investigated & corrected manufacturing discrepancies. Analyzed

& resolved flight crabs. Gathered & Maintained SPC data for continuous quality improvement

purposes.

Sr. Liaison Engineer, MRB

Reviewed, analyzed & dispositioned discrepancies surrounding flexible bus manufacture.

Performed MRB, conceived & initiated Standard Repairs. Wrote corrective action

documentation.

Grumman Aerospace Co, Milledgeville, GA

Sr. Manufacturing Engineer 4/79 to 6/84

Methods & tool order planner. Responsible for manufacture of all composite components

used on EF-111 aircraft. Tool planner for metal bond structure. Planner, US Postal delivery

vehicle components, metal & composite.

Industrial / Materials & Processes Engineer

Responsible for time studies, equipment placement, crew loading. Responsible for raw material

selection & purchasing. Planner, autoclave cycles.

Grumman Aerospace Co, Bethpage, NY

Production Superintendant

Metal and Composite Operations 10/69 to 3/79

Responsibilities: Managing the activities of five manufacturing departments with a foreman

over each with between 400 and 600 people depending on work load. Managed five aircraft, two

spacecraft, and multiple research and development programs. Direct reports included supporting

engineering, tooling, and production support disciplines.

Composite experience includes working, RTM, Resin Transfer Molding. VTRM Vacuum Resin

Transfer Molding Autoclave curing, (1) 4'x 20'ALCO (4) zone electrically heated up to 410F and

180 psig. Four vacuum lines controlled from 2" to 30"HG. (2) 10' x 30'M.C.GILL convection

heated by hot oil transfer up to 410F and 250 psig 24 vacuum lines controlled from 2" to 30"

HG. (1) 10' x 30'DEVINE conduction heated by hot oil transfer up to 410F and 250 psig 4

vacuum lines controlled from 2" to 30" HG. (1) 3'x4'M.C.GILL convection heated electrically

heated up to 800F and 250 psig 4 vacuum lines controlled from 2"to 30"HG. All the above

Autoclaves operated in a CO 2 atmosphere. All above vacuum systems can be vented to

atmosphere. Experienced in the use of layup procedures, cure cycles, and after bond trim tooling,

and hardware installation. Familiar with tooling manufacture from simple laminated thru

"INVAR" and costing application.

Materials Used

Graphite/Epoxy,Boron/Epoxy,Quartz/Epoxy,Kevlar/Aramid,Polyester/Fiberglass.

Use of GR/EP honeycomb, Nomex and Metal honeycomb core materials.

Education: BSME, State University of New York, Farmingdale, NY.

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