Engineer Quality Assurance

Douglas E Albl

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

Duncan, South Carolina 29334

United States E-mail: ***********@***.***

Home: (864) - 905-9966

Work A distinguished career in aviation, aerospace and gas turbine energy

Experience industries with a history of innovation and leadership. Accomplished

in project management, engineering, auditing, inspection, quality,

compliance, operations, manufacturing, processing, safety, root

cause analysis and continuous improvement with 26 years of combined

military, government and commercial experiences. A proactive and

resourceful forward thinker possessing proven ability to get work

done in extreme conditions via decisive decision making real time

under continuously changing environment, conditions, situations and

personnel. 2nd Masters Degree underway in Quality Management with

Six Sigma Black Belt Certification.

Experience at a glance:

26 years combined experience in Manned Space Flight (Space Shuttle),

Gas Turbine technologies, Aircraft & Powerplant Maintenance, Project

Management, Manufacturing, Aircraft MRO, Production, Lean

Processing, Failure/Root Cause Analysis, Customer Focus, Strategic

Planning, Program Management, Quality Controls, Audits, Inspections,

Safety and Compliance.

Crew Chief for FA-18 Hornet in USMC with extreme, fast paced flight

operations and flight-line maintenance to depot level maintenance on

aircraft and gas turbine powerplants.

Site Engineer/Manager for Gas Turbine engine overhaul, assembly,

troubleshoot and test for customer delivery

Test Operations Lead on Space Shuttle Program with extensive

experience in critical path orbiter maintenance operations and

working daily in cross functional role and across all engineering

disciplines.

Lead Engineer and Project Manager for Energy producing Gas Turbine

Field modifications and upgrades averaging $7.5M. L6S Greenbelt

(DMAIC & DFSS) certified.

GAS TURBINE LEAD ENGINEER - General Electric 08/2008 to 07/2010

As the Lead Requisition Engineer I am responsible for integration of

the various organizations in Power Generation Engineering for

complex Conversions, Modifications and Upgrades (CM&U) on Energy

producing gas turbine units from customer contract receipt to

conversion to work schedule to on-site incorporation and

modification completion. The Lead Requisition Engineer has prime

responsibility for translating contractual requirements, schedules

interfaces and ensuring that the contract/order needs are

recognized, understood and satisfied. Lead Requisition Engineer

creates project schedule and schedules all Design Engineering groups

required to satisfy the customer scope & deliverable within the time

constraints. I provide guidance to Design Engineers scheduled for

all project activities as well as mentoring new engineers to create

a working environment that not only challenges them but inspires

them to produce their best work. Ensure all work is completed and in

compliance with engineering instructions and drawings, L6S DMAIC &

DFSS Quality Standards and ISO 9001 standards. Lead Requisition

Engineer will analyze customer order/contract and organize

customer/internal meetings, as needed, to obtain and communicate

complete technical definition of project. Assure that all

engineering work is identified and defined within customer contract

and conflicts are resolved. Define and order all material(s)

required for project ensuring all parts, material arrive on site in

a timely manner to meet project schedule. Review Design Engineering

and Drafting entries to assure technical accuracy, compatibility and

completeness. Monitor engineering schedules and take preventative

action to eliminate schedule delays/misses. Resolve any schedule

conflicts via work-arounds and permanent resolution in parallel.

Determine what equipment is necessary from suppliers based on

supplier certifications and workloads. Implement "late-breaking"

customer changes to contract and determine cost adjustments. Ensure

that customer changes are documented and distributed to all assigned

engineers, drafters and other team members. As a customer

deliverable, I create Unit Modification Reports (customer

deliverable) ensuring all unit modification details are accurate and

complete; all quality procedures are adhered to; all US & European

Union Compliance requirements are met and documentation is complete

and present; Vendor and supplier documentation is complete and

present; Final review of technical package presented to customer

verifying complete technical and equipment definition and all

installation instructions. Daily interaction with all engineering

teams, Manufacturing, Sourcing, Purchasing, Vendors and Suppliers to

ensure understanding of the project requirements and their roles in

producing an accurate deliverable on time and within budget.

Frequently required to identify solutions to problems where no

previous experience or solution exists some of which may be

competing. Responsible for decisions made to problems that can

affect other dept, group or activities in other areas.

SPACE SHUTTLE MAIN ENGINE PRODUCTION & PROCESS QUALITY LEAD - Pratt

& Whitney Rocketdyne 09/2007 to 02/2008

As Quality Lead on Space Shuttle Main Engines (SSME) and SSME ground

support equipment (GSE), I ensure Space Shuttle Main Engines are

certified for flight. As quality lead I am responsible for the

assurance of the engineering instructions accuracy, technical

content and work step completion to the letter with special emphasis

on attention to detail and safety. Quality lead verifies and/or

witnesses conformance to company quality control & assurance

initiatives, policies & procedures, customer requirements, ISO

compliance and Federal regulations for all SSME modifications,

maintenance, & system final closeouts for flight. Quality Lead

ensures adherence and compliance of QMS by audits of work in

progress. By random audits of all work procedures, previous work

performed, relevant databases, training links and content, computer

links/sites contain the current revision of quality procedures and

compliance documents as well as ease of access to/ease of locating

these critical documents. Extensive experience with flight hardware

processing such as hazardous engine lifting operations

(installations/removals), hypergolic haz ops requiring SCAPE and/or

confined space entry, electrical bonding, connector mate/demates,

torque/safety wire, digital photo closeouts, Lock Out/Tag Out, FOD,

bolt stretching, tool control/calibrations, GSE proof-loading.

Extensive experience with flight hardware inspection methods such as

mold impressions, borescope inspections, dye penetrant, eddy

current, ultrasonic, X-ray, optical comparator, creating step by

step inspection instructions, drawing & specification requirements,

analyzing inspection results, use of precision measuring devices,

root cause analysis and witnessing SME closeouts on launch pad

requiring confined space entry certification. (NASA govt security

clearances In-active).

SPACE SHUTTLE OPERATIONS ENGINEER/TEST CONDUCTOR - United Space

Alliance 09/2002 to 09/2007

As Test Conductor, my responsibilities within Launch Operations

include managing all work on the space shuttle orbiter, ground

support equipment (GSE), facility operations coordination, parts and

work integration as well as electrical, hydraulic, water and

pneumatic systems testing. Test Conductor is the single point of

contact for coordinating maintenance on the orbiter, associated

flight hardware and outside support required. Test Conductor

receives work status throughout the shift from the shop leads and

managers to ensure schedule integrity and identify issues/work

stoppages requiring resolution. The test conductor group "owns" the

space vehicle closeout documents. I was tasked with a complete

revision of the shuttle midbody closeout for flight documents (FWD,

MID, & AFT). These three documents contain thousands of pages each

respectively. They contain repairs, multiple systems checks &

verifications, component installations & inspections, photo

documentation, detailed step by step work instructions. Such as 100%

coverage structural inspections using technology designed to detect

surface and subsurface voids, defects, anomalies-any

foreign/undesired presence. Welding, rivet, bracket/brace attachment

inspections. Miles of wire harness installations, clamping, repairs

and subsequent inspections for each. Installation of pneumatic,

water and hydraulic lines, clamping and subsequent inspections for

each. Inspections specific to the overall vehicle integrity.

Identify all hazards in performing this work. Identify all outside

support required and those step by step work instructions. These

documents contain hundreds of Hazardous Warnings, Cautions, and

General Notes. These documents include extensive quality control

measures, mistake-proofing wording, Human Factors elements, lessons

learned, best practices and changes resulting from investigations.

Space Shuttle Closeout documents are the final authority documents

for preparing the vehicle for spaceflight. The Test Conductor has

the authority and responsibility to provide real-time solutions to

schedule impacts, re-prioritize work tasks, and flow changes to

upper management, NASA test director, scheduling and planning

departments to reflect these changes in orbiter flow database for

visibility and ease of access to latest work status and schedule

changes. The Test Conductor must possess an understanding of all

engineering disciplines. Test Conductor is responsible for knowing

and clearing constraints of critical path work. Test Conductor runs

shift tie-in meetings with United Space Alliance (USA) team, Boeing,

NASA, Safety, Quality, Flow Management, Vehicle Operations Chief,

security, engineering personnel, and shop leads providing on coming

shift with job priorities and status of work in progress. Perform

quality escape investigations and present findings via oral

presentation, MS PowerPoint slide shows, visuals, handouts, failed

parts, drawings, actual photos, written statements, historical

records/trends and videos. Severity/Criticality of the event

determines which or all of these methods are used. I am FEMA

certified Incident Commander for all emergencies and evacuations in

the processing facility.

V2500 FIELD ENGINEER/SERVICE MANAGER- International Aero Engines, AG

07/1999 to 09/2002

Serve as point of contact, host and resident technical manager for

V2500 Gas Turbine Engine program. Work with NDI team to

evaluate/inspect parts via eddy current, magnetic particle,

ultrasonic, dye penetrant. Manage engine overhaul and repair

processes and customer account(s), which includes customer interface

discussing all shop and business issues and management of contract

execution and interpretation, financial deliverables (estimates and

invoices), customer satisfaction improvement initiatives, and

quality/safety engineering. Host meetings with customers to gain

customer perspective and expectations working together to address

warranty issues and entitlements, engine modification options,

engine maintenance status, engine inspection cycles and product life

extension. Manage engine overhaul work and schedule as well as

manage workmanship quality in union shop and responsible for engine

part accept/rejection criteria, disposition and rationale. As a

Service Manager, I was able to get work completed on time and meet

deadlines where others could not through a critical and valued

relationship with the union technicians and inspectors. This team

approach helped everyone involved by providing sense of value, worth

and accomplishment. Responsible for compliance with manufacturer

maintenance procedures and Federal Aviation Administration

regulations for air carrier airworthiness. Responsible for

developing, managing and implementing real-time solutions to any

engine processing impacts. Proven success in engine maintenance

cycle time reductions by developing innovative processing concepts

such as engine part and sub-assembly substitution/rotation,

definition of engine maintenance flow process and subsequent floor

plan functional and physical design as well as developing part

tracking system from receiving dock to logistics to engine

installation for multiple product overhaul facility.

TECHNICAL SUPPORT ENGINEER - Pratt & Whitney 05/1998 to 07/1999

Responsible for development of engine center policy, requirements,

guidance and performance of engine overhaul and quality assurance

activities required to ensure that manufacturer maintenance

procedures are complied with and Federal Aviation Administration

regulations are clearly understood and adhered thus producing

aircraft engines, systems, subsystems, and associated parts that

will perform desirably in severe aircraft flight operations. Provide

maintenance and inspection recommendations based on research,

experience, historical trends and company lessons learned to Pratt &

Whitney field representatives, aircraft operators, and engine

overhaul shops ensuring quality of maintenance and procedures as

well as maintaining consistent and reliable information channels to

customers and management. Responsible for reviewing internal

maintenance manuals for accuracy and incorporating revisions,

service bulletins and manufacturing modifications prior to their

released, providing the most current information available. Daily

conference calls with international engineering partners to

identify, analyze, discuss and troubleshoot such topics as engine

in-flight anomalies, engine performance issues, and part design

life.

SENIOR MECHANICAL TECHNICIAN - Pratt & Whitney USBI 03/1994 to

05/1998

As a senior mechanical technician on space shuttle solid rocket

boosters for manned space flight I performed preflight build-up of

solid rocket forward and aft booster segments, postflight visual

inspections, damage assessment, thermal ablative removal, actuator

removals, booster separation motor removal, electrical & mechanical

systems checks. I also assumed additional duties as quality

assurance specialist, conducting quality inspections on maintenance

performed by peers on Solid Rocket Boosters and Ground Support

Equipment. Stack and move booster segments using mobile and overhead

cranes. As a senior mechanical I maintain and inspect robotic and

hydrolase systems for solid rocket thermal ablative removal

operations. Conduct Quality Assurance surveillance and oversight

activities of contractors' work performed and quality assurance

activities on flight hardware and GSE. Perform inspections of solid

rocket boosters customer provided experiment, flight and GSE

hardware. Established, and maintained quality assurance programs

through all phases of the development and implementation for solid

rocket Forward Assembly and Aft Skirt, associated systems and ground

support equipment.

CREW CHIEF/MANAGER F/A-18 Hornet- United States Marine Corps 02/1986

to 03/1997

Managed F/A-18 Hornet Aircraft & Engine (F404) maintenance,

prioritized maintenance activities and assigned work tasks. Managed

all powerplant and related system maintenance and work stoppages.

Managed flight-line operations, quality assurance, and safety

programs. Trained new Marines in all areas of engine, APU, generator

and aircraft maintenance, inspections, principles of operation,

safety, and quality. Interpreting aircraft maintenance codes and

analysis, hazardous operations and emergency discipline. As shop

manager and senior Collateral Duty Inspector and trainer

(CDI-military aviation quality inspector) responsible for monitoring

and final inspection of all engine, APU and fuel cell work

performed, including engine installations, engine part

installations, fuel cell/fuel cell valve/piping installation and

maintenance, APU removals/installations, generator

removals/installations, engine lubrication/chip detector

inspections, engine preventative maintenance inspection intervals ie

100/200 hour inspections, safety discrepancies and part flight

worthiness. Borescope Inspections. Engine low power and APU power-up

qualified. Engine test cell (Hush House) 2nd shift supervisor (El

Toro, CA Base). Responsible for engine system verifications,

accuracy of documentation and 100% compliance. Additional management

responsibilities include powerplant readiness to support aggressive

flight schedules/operations. Managed aircraft publications program

and revisions as well as service bulletins, engine maint and service

manuals, technical directives, engineering changes, schematics,

engineering drawings, engine fuel and oil logs.

Education National Graduate School, MA-Masters of Science, Quality Management

w/ Lean Six Sigma Black Belt Certification (In Progress)

Relevant Coursework: System Approach to Strategic Planning,

Performance Based Management, Project Management, Benchmarking,

Improving Throughput-Learning to See, DIVE Investigations, Supply

Chain Productivity & Management, Root Cause & Mistake Proofing,

Applied Statistical Analysis, Financial System Management,

Organizational Performance Assessment.

University of Miami, Miami, FL- Masters of Science, Engineering

Technology;

Relevant Coursework: Statistical Quality Control & Management;

Marketing Management; Technology Management; Project Management;

Strategic Management; Engineering Cost Management. Production/Flow

Management, Microsoft Project, ANOVA, Experiment Design.

Albertus Magnus College, New Haven, CT- Bachelors of Science,

Business Management/Computer Engineering Minor;

Relevant Coursework: Management and Leadership, Written/Verbal

Communication, Information Systems, Statistics, International

Business, Computer Applications, MS Word, Excel, PowerPoint,

Computer networks, Java, Basic Language, C++, Industrial Quality and

Safety.

Additional Naval Air Technical Training Center; Millington, TN-

Training/ Aviation Training C-000-2010, Aviation Familiarization 641, Aviation

Certificatio Machinist/Turbine Engine Theory C-601-2010

ns Aircraft Maintenance MCE-6000, Aircraft Mechanic MCE-6011,

A-4/TA-4/QA-4/ Aircraft Mechanic 6012

Maintenance Technician NV-1704-0157

Naval Air Maintenance Training School; Cecil Field, FL

F/A-18 Power Plant C-601-3866, F/A-18 Practical Job Training

D-600-0608, F/A-18 Power Plant and Related Systems, F/A-18 Aircraft

Mechanic/System Specialist 6017, Corrosion Control C-600-3180,

Aircraft Airframe Maintenance & Inspection, Aviation Maintenance

Technology, Industrial Safety, Field Management, Metals/Alloys,

Mechanical, Electrical, Hydraulic, Pneumatic Systems, Maintenance

Management, Personnel Supervision.

Marine Corps Institute; Washington D.C

Marine Corps Leadership 033M

Supervisory Management MC-1406-0023

Pratt & Whitney: Gas Turbine Engine Design (24 hours)

Dealing with Difficult People, Win-Win Negotiations, Building

Customer Relationships, Active/Interactive Listening, Customer Score

Cards.

International Aero Engines: V2500 Engine Maintenance/Operations.

Customer Focus, Voice of Customer, Team Building workshop.

National Emergency Training Center ICS-100 Incident Command System

(ICS), 2006

National Emergency Training Center ICS-200 ICS - Single Resource &

Initial Action Incidents 2006

National Emergency Training Center ICS-700 Nat'l Incident Management

Systems (NIMS) 2006

National Emergency Training Center ICS-800 National Response Plan

(NPR) 2006

NASA Training:

NASA: Level II Visual Testing, Inspection techniques, Quality

Assurance Inspector, QA Auditor. 6K/16K/30K Forklifts, 5/15 Ton

Cranes, Mobile Crane, Haz/Toxic Waste Management, Chemical Safety,

High Press Gas Safety, Drawing Comprehension/Interpretation,

Engineering Orders, Cryogenic Safety, CPR & Elect Shock, Program

Critical Hardware, Working at Heights.

PROFESSIONAL LICENSES/CERTIFICATES

NASA: Level II Visual Testing certification

Previously held for 15 years Commercial Drivers License for all

weight vehicles with Doubles/Triples and Hazardous Material

Endorsements.

FEMA: National Incident Management System and Incident Command

federal certifications

PROFESSIONAL RATINGS, AWARDS, AND RECOGNITIONS

Meritorious Mast (VMFA-531) - Marine Corps

Safety Award (VMFA-142) - Marine Corps

Letter of Appreciation-International Aero Engines

Achievement Award-United Space Alliance

PROFESSIONAL AFFILIATIONS

Food for Life Ministries, Angel Food Ministries, Habitat for

Humanity, American Cancer Society, National Kidney Foundation,

Church mission trip to Honduras, Surfrider Foundation.

FOREIGN TRAVEL

Hong Kong, Germany, Japan, Honduras, Korea, French Polynesia,

Canada, Philippines, Wake Island, Italy, Belgium, Mexico, Iwo Jima

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