Manager Engineer
Resume:
Hai T. Cao
Bothell, WA 98021 *****@*****.***
SUMMARY
Versatile, bilingual Program Manager with expertise in electronic manufacturing. Experienced in all phases of new
product development and introduction, with emphasis on design for manufacturability, testability, and reliability. Proven
leadership skills in a matrix organization. Recognized as a methodical problem solver and a team player. Communicate
effectively with all levels in the organization. Detailed knowledge of:
• •
Lean (Six-Sigma) Environmental/susce
manufacturing ptibility/system test.
• •
Customer/Supplier Quality Engineering
liaison standards and practices
• •
Profit and Loss Military/Governmen
performance t/Industry standards
• •
Failure Mode Effect Specification
and analysis interpretation and compliance
PROFESSIONAL EXPERIENCE
AEROJET, REDMOND, WA 1990 - 2009
Industry leader of high quality and reliability manufacturer of space propulsion systems.
Operation Program Manager, 2002 - 2009
Provided technical direction to the power processing unit (PPU) IPT team of the Transformational Communication
Satellite (TSAT) for compliance with customer specification and manufacturability. Resolved manufacturing problems
of the $1.5M Advanced Extremely High Frequency (AEHF) PPU. Chaired the internal electronics Material Review
Board (MRB).
• Developed the Space Electronics lessons learned data base and led the brainstorming session of the “Do’s and
Don’ts” for the design team of the TSAT PPU.
• Presented to senior management and obtained approval for a concurrent development team of test system for the
TSAT PPU.
• Managed the failure investigation and analysis team who identified the design oversight of the AEHF PPU and the
corrective actions for both the design and the already built, shipped units.
• Planned and directed team who executed the electronic data base for the massive pre-launch AEHF PPU system
audit. Achieved enormous success with only one minor “concern” from Lockheed Martin Space System, my
customer. Resulted in $150K under budget.
• Awarded exemplary leadership in the delivery of eight AEHF PPU’s under a very aggressive recovery schedule.
• Completed the AEHF PPU program with $1.0M profit.
Sr. Principal Quality Engineer, 1996 – 2002
Provided technical support to the AEHF PPU IPT team and the Enhanced Power Control Unit (EPCU) manufacturing
team. Chaired the MRB. Interfaced with Lockheed Martin Space System, the customer, for all technical concerns.
Implemented in-circuit test for all new circuit card designs of the new AEHF PPU.
Visited with suppliers for key sub-assemblies, i.e. printed wiring board, transformer, relays to assure all technical
requirements and specifications are effectively communicated.
• Developed a process to test the integrity of Field Programmable Gate Array (FPGA) after leads were severely bent.
Realized a saving of >$100K.
• Used “Lean” manufacturing tools to lead the effort which reduced the EPCU cycle time by 30%.
Program Manager/Principal Quality Engineer, 1993 – 1996
Promoted to Program Manager of a cross-functional team that manufactured and delivered the S7000 Power
Conditioning Units (PCU) on schedule and within budget.
• Managed team effort which simplified process flow, resulted in profit that surpassed goal.
Hai T. Cao 206-***-****
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• Achieved total customer satisfaction with all 60 S7000 PCU’s have performed flawlessly in orbit.
Sr. Quality Engineer, 1990 - 1993
Started as program quality engineer for a first ever Space Electronics program, the TELSTAR 4 PCU and for all follow-
on PCU programs: MELCO, A2100, Triana. Interpreted customer specifications and compliance for Space Electronics
product development teams. Interfaced with customers and government agencies. Co-developed manufacturing
instructions. Communicated with key suppliers for specifications compliance. Chaired Failure Review Board meetings.
• Led the team who implemented Statistical Process Control (SPC) for the company.
• Developed, implemented, and trained others to identify key characteristics of the designs.
• Managed the team who achieved certification to Boeing AQS D1-9000 and ISO-9001.
• Led the team who designed, qualification tested, and FAA certified for the Boeing 777 Dimmer Control Unit (DCU).
• Supported development, qualification, and production of the In-flight Entertainment system.
Advanced Technology Laboratories (ATL), BOTHELL, WA 1986 - 1990
A leading edge medical electronics company specialized in Ultrasound machines.
Manager of Quality Engineering
Managed a team eleven direct reports with an annual budget of $800K. Interfaced with customers and government
agencies. Provided technical direction to new product development teams for compliance with Federal Drug
Administration (FDA) requirements. Supported clinical trials. Conducted internal audit for compliance with Good
Manufacturing Practices (GMP). Led supplier quality, failure investigation and analysis, and customer complaint
functions. Published quality metrics.
Fluke Corporation, EVERETT, WA 1985 - 1986
Recognized for affordable high quality and reliability electronics test equipments.
Manager of Manufacturing Engineering - Led a staff of eleven with an annual budget of $ >500K. Provided technical
input to the new product development teams. Led problem resolution for manufacturing issues. Consistently operated
within budget.
Harris Corporation, MOUNTAIN VIEW, CA 1982 - 1985
A conglomerate with products ranged from semiconductors to transmitters and receivers.
Manager of Manufacturing Engineering and Quality Assurance - Led a staff of seven. Provided manufacturing and
quality requirements to Design Engineering. Resolved problems in manufacturing. Managed all quality functions.
General Electric, FAIRFIELD, CT 1980 - 1982
Manufacturing Management Program Trainee - Served as manufacturing engineer, production scheduler, and
inspection supervisor at GE Calma, GE Nuclear Energy in San Jose, California and at GE Major Appliances in
Louisville, Kentucky.
EDUCATION
University of Washington - Seattle, Washington - Bachelor of Science in Industrial Engineering.
San Jose State University - San Jose, California - Attended Graduate Program in System Engineering.
General Electric Company - Fairfield, Connecticut - Graduated from the Manufacturing Management Program.
TRAINING & DEVELOPMENT
Program Management - Writing Winning Proposal.
Dale Carnegies Communication - Negotiation skills.
Lean “Six-Sigma” Operation Green Belt Certified.
PROFESSIONAL AFFILIATIONS
Hai T. Cao 206-***-****
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Past Seattle Section Membership Chairman of American Society of Quality (ASQ)
COMMUNITY SERVICES
President of Bothell Girls Select Basketball
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