DONALD C. HAINLEY

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

Waynesville, OH 45068

Phone: 937-***-****

Cell: 937-***-****

Email: abnfl1@r.postjobfree.com

SUMMARY

Versatile leader with significant design, development, R&D, manufacturing,

customer support, and management experience. Have held positions of varying

and increasing responsibility throughout career and been successful with

them. Have always been a hands on manager that not only managed, but ran

own projects. Knowledgeable about aerospace and non-aerospace materials and

manufacturing processes including cold and hot forming, machining, brazing,

welding, and assembly techniques. Able to integrate engineering knowledge

and business sense into proper solutions.

PROFESSIONAL EXPERIENCE:

October, 2009- TURBO-COMBUSTOR TECHNOLOGY INC.

Cincinnati, OH

Present Position: Business Unit Leader

. Profit and loss responsibility for business unit comprised

of small Rolls Royce machined components, ground power

vane cooling EDM, and fast hole EDM of sheet metal

components

. Provide day-to-day leadership, direction, and support for 5

manufacturing engineers, 4 supervisors, and 25 floor

personnel

. Initiating new NPI procedure to involve proper personnel at

earlier stages of part development to more smoothly and

quickly bring parts into production

. Introduced visual management system of fast hole floor area

. Initiated visual scheduling and capacity management system

May, 2006- BARNES AEROSPACE - ADVANCED FABRICATION. DIV. West Chester, OH

July, 2009 Positions: Engineering Manager & Business Development

Manager

. Provided day-to-day leadership, direction, and support for

7 manufacturing engineers, an estimator, 2 tool designers,

2 CNC programmers, and 10 tool makers in a $35M/year build-

to-print aerospace facility whose primary product was cold

and hot formed engine components, assemblies, and honeycomb

seal structures

. Led new product introduction and manufacturing improvement

efforts

. Provided direct technical support and estimating and

proposal activities for sales force and performed customer

presentations of proposals and facility capabilities

. Key lead in bringing in $6M in new annual sales for CY 2010

primarily by cultivating and supporting new, non-US

customer base

. Responsible for identifying, justifying, and implementation

of technology and capital improvements for the division

with an estimated yearly investment of $500K

. Day-to-day project planning, program management, budgetary

and manpower planning responsibilities

. Acted as Lean Leader mentor and developed lean schedule and

capacity plan for division

October, 2004- WALL COLMONOY - DAYTON

Dayton, OH

May, 2006 Position: General Manager

. Profit and loss responsibility for 20 person contract

braze, coating, and specialty heat treating operation

. Stabilized sales at $2.3M/year in a declining market

. Forecasted and obtained sales of >$2.8M in 2006

. Instituted customer focused organization and metrics and

maintained > 95.2% on time delivery and >95.8% first time

braze yields

. Led involvement in fuel cell heat exchanger fabrication and

performed ASME calculations in support of project

DONALD C. HAINLEY

June, 2003- SMITH'S AEROSPACE - TITEFLEX DIVISION

Springfield, MA

October, 2004 Position: Technical Director - Aerospace

. Provided day-to-day leadership and direction for 4 research

engineers, 6 application engineers, and 3 manufacturing

engineers for $25M+ aerospace hydraulic hose company

. Realigned groups to facilitate better communication between

shop floor and R&D activities

. Implemented design improvements and established design for

manufacturability criteria

. Led efforts to validate and certify 5,000 psi Teflon/Kevlar

hose line

. Responsible for project management and budget of R&D

activities

January, 1994 - PARKER HANNIFIN - UAP DIVISION

Forest, OH

June, 2003 Position: Chief Engineer/Engineering Team Leader

July, 2002- June 2003

. Led all design engineering and quality functions for $20M+

aerospace heat exchanger division that fabricated both

plate-fin and shell and tube units

. Responsible for 4 design engineers, 4 quality engineers,

and test lab

. Led manufacturing and yield improvements

. Established design for manufacturability and assembly

criteria

. Established engineering standards for heat exchanger stress

analysis

. Developed novel heat transfer surface characterization

method and implemented test facility in conjunction with

Ohio Northern University

. Rewrote FAA Repair Station manual to bring repair shop into

compliance

. Led and performed fuel cell heat exchanger development for

a system that included condensers, recuperators, and

preheaters

. Developed patent concept and application for hybrid plate

and fin concept

. Provided engineering estimates for projects and prepared

engineering budget

Position: Operations Team Leader/Lean Leader

September, 1999 - June 2002

. Profit and loss responsibility for daily manufacturing

operations of $20M+ heat exchanger aerospace company

. Conducted manpower planning, scheduling and capacity

analysis for 80 person work force

. Consistently achieved >93% on time delivery

. Reduced overtime from 22% to 5% in ten week period

. Developed and maintained $750K yearly operating budget

. Directed 4 shop supervisors, 4 manufacturing engineers, and

6 man tool room

. Led implementation of Lean Manufacturing and Best Practices

for the division

. Created and led teams that:

o Increased first time yields from 15% to >85%

in less than 6 weeks

o Reduced final assembly floor space by 35% in 1

week

o Reduction of rework by >50% on sheet metal

components

Position: Business Team Leader

January, 1998-August, 1999

. Responsible for all profit and loss aspects of

entrepreneurial venture for a non-traditional product for

the division: high efficiency, thin fin, heat sinks

. Direct day-to-day supervision of 3 shift operation and

leadership of business unit

. Developed product design and manufacturing methods

. Established, justified, and recommended capital

expenditures

Position: Senior Product Engineer

January, 1994-December, 1997

. Performed all aspects of aerospace heat exchanger

development including:

o Verifying overall design requirements were met

o Thermal and fluid analysis

o Stress analysis including finite element work

. Wrote reports, procedures, proposals and qualification

reports for customer review

. Responsible for drawing development and approvals

. Supported and addressed manufacturing problems

. Performed layout and other functions on CATIA CAD system

. Rewrote the heat exchanger design and analysis code for the

division

DONALD C. HAINLEY

September, 1989- GRIMES AEROSPACE COMPANY

Urbana, OH

December, 1993 Positions: Project Engineer & Manager, Heat

Exchangers

. Performed all aspects of aerospace heat exchanger design

and development

. Prepared engineering budget and cost estimates

. Responsible for drawing development and approved all

drawings for group

. Wrote reports, proposals, procedures and qualification

reports for customer review

. Key lead in development of knowledge based heat exchanger

design software in conjunction with Ohio State University

. Supported and addressed manufacturing problems

October, 1987- SVERDRUP TECHNOLOGY INCORPORATED

Cleveland, OH

September, 1989 NASA LEWIS RESEARCH CENTER GROUP

Position: Heat Transfer Engineer

. Designed and characterized heat rejection radiators for

future space power systems

. Developed concepts and layouts of heat pipe systems for

lunar base concepts

. Performed technical oversight of contracts dealing with

development of heat rejection systems for NASA

. Assisted in thermal issues associated with Sterling engines

. Provided technical review comments to SBIR proposals

August, 1985- BABCOCK & WILCOX

Barberton, OH

October, 1987 NUCLEAR EQUIPMENT DIVISION

Initial Assignment: Functional Engineer

. Evaluated heat transfer and fluid flow analysis on naval

nuclear equipment propulsion systems heat transfer systems

including steam generators and pressurizers

Subsequent Assignment: Project Engineer

. Performed day-to-day shop support from a design engineering

perspective

. Evaluated manufacturing problems that affected function or

structural adequacy of system and prepared analyses for

customer acceptance

. Responsible for review of drawings to endure design

adequacy and manufacturability were achieved

EDUCATION:

1996-1998 OHIO STATE UNIVERSITY

Columbus, OH

. Received MBA while attending school part time in the

evenings

. Graduated 3rd among night students

. Recipient of Weidler Scholar Award and Award for Academic

Excellence

. GPA: 3.80

1988-1989 CASE WESTERN RESERVE UNIVERSITY

Cleveland, OH

. Attended school part time to fulfill Mechanical Engineering

Ph.D. course requirements

. GAP: 3.67

1984-1985 PENNSYLVANIA STATE UNIVERSITY

University Park, PA

. Received Masters of Science Degree in Mechanical

Engineering

. Primary focus was heat transfer and enhancement methods,

and combustion

. Research topic: fluidized bed coal combustion

. Recipient of Deans Fellowship

. GPA: 3.61

1980-1984 PENNSYLVANIA STATE UNIVERSITY

University Park, PA

. Received Bachelor of Science Degree in Mechanical

Engineering

. Recipient of Ingersoll-Rand Scholarship

. Participated in University Scholar's Program

. Graduated with Honors and Highest Distinction

. GPA: 3.90

DONALD C. HAINLEY

WRITINGS: Have authored or co-authored five publications dealing with

Fluidized Bed Coal Combustion, Heat Pipe Heat Exchangers, and

Knowledge Based Heat Exchanger Design Systems. Publications

date from 1986-1992

MISC: Professional Engineer - State of Ohio - license not currently

active

Have held DOD Secret and DOE Level L security clearances

REFERENCES:Furnished upon request November,

2009

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