Engineer Design

RICHARD W. (RICK) HENSLEY

***** **. ***** **.

De Soto, MO 63020

Home: 636-***-****

SUMMARY

Twenty-eight plus years experience in Team Leadership, engineering design, production support,

research, development, technical leadership, and customer support in the aerospace and automotive

industries. Experience includes:

Fluid Systems (fuel, hydraulics, environmental control, oxygen, fire protection) design

Powerplant installation design.

Fluid system component detail design

Fluid fitting detail design and development

Specialized fitting research, design and development

System and component failure analysis

Direct technical support of government and commercial customers

3000 hr. UGII (through V10), 6000 hr. CADD

Direct tooling design and support of a highly automated production line

4000 hr. AutoCAD 3D (through AutoCAD V2005)

EXPERIENCE

1998 thru 2008: DaimlerChrysler AG / Chrysler LLC,

St. Louis Assembly Plant South, 1001 North Highway Drive, Fenton, MO 63026

Tool and Process Engineer, Body-In-White (BIW) Department, Minivan Assembly

Responsible for all geometry setting, manual interface, and torque control tooling in BIW

Reviewed and approved new BIW tooling for RS (2001 MY), S&G (2005 MY), & RT (2008 MY)

launches

Procured and maintained tooling and spare parts required to support new vehicle launches, and

sustain production at 76+ vehicles per hour

Designed, or redesigned numerous tools and fixtures to improve vehicle quality, production rate, and

reduce cost

Designed and implemented an in-house alternative to supplier’s concept for conveyor carrier

modification to accept new product, on two different occasions. Each mod program saved over

$250,000 vs. the supplier’s concept.

1995 to 1998: Raytheon Aircraft Company, PO Box 85, Wichita, Kansas 67201

Integrated Product Team Leader, Hawker Horizon Fuel System, and Fire & Overheat Protection System

Established Fuel System baseline design and configuration to meet FAR Part 25 requirements

Led multi-national team to define and create design of Fuel System for new “clean sheet” airplane

Coordinated supplier selection process for Fuel System, and Fire & Overheat Protection System

Coordinated and approved component, and installation designs to meet system requirements

Conducted full scale fuel system development test program at FHI in Japan, as well as final testing at

Wichita facility

Conducted industry surveys to establish baseline design for Fire and Overheat Protection System to

meet FAR Part 25 requirements

Appointed as a member of Fuel Tank Harmonization Working Group, Aviation Rulemaking Advisory

Committee (created as a result of the TWA Flight 800 incident)

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RICHARD W. (RICK) HENSLEY

1985-1995: McDonnell Douglas Aerospace, PO Box 516, St. Louis, Missouri 63166

Increasing design and leadership responsibilities on various military and commercial projects.

08/95-09/95: Senior Project Engineer, F-15 Fuel System Design

Led a design study group to add a Navy Style In-Flight Refueling Probe to the F-15

06/95-08/95: Senior Project Engineer, Joint Advanced Strike Technology Project

Conducted APU and Main Engine installation studies for new joint service fighter proposal

02/95-06/95: Senior Project Engineer, AV-8B Harrier Advance Design

Conducted Fuel and Environmental Control System installation studies for new configuration

concepts

Conducted Hydraulic Vulnerability Improvement Study in conjunction with the Naval Weapons Center

at China Lake

09/92-02/95: Lead Engineer / Senior Project Engineer, T-45A Goshawk Fuel System Design

Led fuel system installation design effort for addition of inlet fuel tanks to the airplane. Incorporated

many improvements that reduced production rework up to 80%, and improved installation

repeatability resulting in significant program savings.

Provided technical leadership for specification, procurement, and qualification of new fuel system

components which required extensive coordination with subcontractors.

7/92-09/92: Lead Engineer, T-45A Goshawk Hydraulics Design

Conducted failure analysis program and established new acceptance test procedures for discrepant

hydraulic brake system components which had grounded the fleet, resulting in customer (US Navy)

authorization to resume flight operations.

01/92-07/92: Lead Engineer, MD-12 Airliner Fuel System Design

Led wing fuel system installation design layout effort (80% of the total aircraft fuel system).

Conducted numerous trade studies to optimize the installation for FAR Part 25 compliance, system

performance, weight, cost, and maintainability.

06/90-01/92: Senior Engineer / Lead Engineer F-15 Eagle Hydraulic System Design

Directed design, and approved supplier data for subcontracted hydraulic system equipment.

Analyzed and coordinated solutions to production, in-service, and subcontractor problems, including

conducting several failure analyses on failed components.

04/88-06/90: Senior Engineer, A-12A Avenger Fuel System Design

Developed new Aluminum / Conductive Elastomer Electromagnetic Interference Seal for use

between carbon fiber composite structure and metallic fittings and components (This new design

saved over $1 Million in the first 7 ships compared to the baseline configuration).

Designed and supervised design of several fuel system installations.

Developed procurement specifications, directed design, and approved supplier data for

subcontracted fuel system equipment.

Designed new redundant seal, replaceable fuel bulkhead fitting system for piping and components

Interface coordinator for fuel system splices between MCAIR and General Dynamics.

MCAIR coordinator for Dry Bay Fire Protection System Installation (this used an optically sensed,

pyrotechnic discharged, linear fire extinguisher).

04/85-03/88: Senior Engineer, AV-8B Harrier Fuel System Design

Designed solutions to in-service and production problems with Fuel, Water, and Secondary Power

System installations.

Coordinated solutions to supplier in-service and production problems, and approved supplier data for

subcontracted equipment.

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RICHARD W. (RICK) HENSLEY

07/83-04/85 & 09/79-09/82: Sabreliner Corporation, 6161 Aviation Drive, St. Louis, Missouri 63134

Increasing customer support and mechanical system design responsibilities on a commercial and

military business jet project.

07/83-04/85: Engineer, Sabreliner and T-39 Mechanical Systems Design (CAR 4B)

Designed and developed solutions to in-service problems with Landing Gear, Hydraulic, Fuel,

Secondary Power, Crew Oxygen, Environmental, and Flight Control Systems

Originated many Service Bulletins, Service Letters, and Optional Kits to resolve service problems,

(required extensive coordination with the FAA Kansas City and Wichita Offices) including:

Designed tooling and procedures for removing and inspecting corrosion in the metering pin

seat (interior) of main landing gear piston.

Designed a complete quick donning crew oxygen mask / regulator installation.

Designed a new Auxiliary Powerplant fuel pump installation to overcome an insufficient fuel

delivery problem.

Investigated and designed a fix for an asymmetrical spoiler deployment problem on the

Sabre 65.

09/79 - 09/82: Maintenance Analyst, promoted to Service Coordinator 02/81, Sabreliner and T-39 Service

Engineering

Identified and proposed solutions to problems with Landing Gear, Fuel, Hydraulic, and Oxygen

systems. For example:

Researched, established, and implemented a treatment program for the Sabreliner fuel

system to control microbiological contamination and propagation.

Coordinated failure analysis effort to determine cause and solution for several brake rotor

catastrophic failures.

EDUCATION

Parks College of Saint Louis University, Cahokia, lllinois 62206

B.S. Aeronautics, Major in Aircraft Maintenance Management, April 1977

A.S. Aeronautics, Major in Aircraft Maintenance Engineering, August 1976

Airframe and Powerplant Mechanic License, April 1974

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