Engineer Manufacturing
Resume:
SEAN EGAN
Email: *********@********.***
Address: UNIT 8
City: ST KILDA, (Victoria 3183, Australia)
State: WA
Zip: 98101
Country: USA
Phone: 347-***-****
Skill Level: Experienced
Salary Range: $90,000
Willing to Relocate
Primary Skills/Experience:
See Resume
Educational Background:
See Resume
Job History / Details:
Please note: I hold dual citizenship a Irish & Australian. As an Australian citizen, once I find a job matching my education (degree in Engineering) I am entitled to work in the USA (on an E3 visa) without need for sponsorship.
a Please refer to the following website: http://canberra.usembassy.gov/e3visa.html.
Curriculum Vitae / Resume
Personal Details
Name: Sean Egan
Address: 8/22 Crimea Street, East St. Kilda, Victoria 3183, Australia.
Phone: +61-406-***-***
Email: *********@********.***
Date of Birth: January 19th 1976.
Nationality: Irish (& Australian Citizen/Passport-holder)
Education
Sep 1999 a Jun 2002: University of Limerick, Ireland.
a BEng Degree in Production Engineering.
(Assessed by ENGINEERS AUSTRALIA: meets academic requirement for a Professional Engineer in Australia)
Sep 1997 a Jun 1999: Limerick Institute of Technology, Ireland.
a National Certificate in Manufacturing Engineering
Sep 1993 a Jun 1996: Athlone Institute of Technology, Ireland.
a Senior Trade Certificate in Motor Car Engineering (Motor Mechanic Apprenticeship)
Engineering Career
Aug 2011 a Present day: Boeing Aerostructures Australia (Melbourne).
Position: Manufacturing Engineer a Composite Fabrication
Roles/Responsibilities:
a Writing qualification plans, conducting qualifications, and then writing qualification reports, after
closing out findings which were encountered during the qualifying of equipment & afly-awaya production parts.
a Integrate the role with operations, support, and management, to ensure process knowledge and lessons learned
from development work, trials and previous manufacturing history are captured and implemented.
a Provision of effective and timely advice as requested from manufacturing managers and engineering personnel.
a In consultation with engineering leadership, provide advice and recommendations concerning improvement and
cost reduction opportunities during the product development phase.
a Provide ME input into product design to ensure product is optimized for manufacture.
a Lead continuous improvement activities to reduce/eliminate manufacturing processes variation.
a Develop, implement and evaluate processes to optimize operational efficiency.
a Provide manufacturing technical guidance, ensuring personnel operate within technical guidelines.
a Support material and manufacturing process development, related to derivate programs and cost reduction
activities.
Aug 2010 a Aug 2011
Position: Manufacturing Quality Engineer (Quality Inspector) a Composite Fabrication
Roles/Responsibilities:
a Writing an extensive training manual documenting every aspect of the cure buy-off procedure for resin
infused parts to promote consistency in the cure buy-off process.
a Producing and maintaining work/manufacturing instructions.
a Monitoring, inspecting and reporting product & process compliance to requirements.
a Perform level aQa stamp inspection (including FAI)
a Perform Operator Verification monitoring audits and monitor operator accreditation
a Maintain SPC charting and review CpK values
a Initiate and follow through the corrective action process to conclusion at cell level.
a Preparation of technical and performance data for program reviews and presentation.
a Provide product and process improvement.
a Provide technical support to cell on a daily basis and liaise with other functional areas.
a Provide technical training in accordance with expressed needs.
a Manually retrieving, and creating a cure report (via an excel spreadsheet), when the oven cure buy-off
software fails.
Sep 2008 a July 2010
Production Parts, Melbourne, Australia.
Position: Manufacturing Engineer
Roles/Responsibilities:
a Project-manage contract requirements from an engineering & production perspective
a Liaising with customer to ensure all components are produced to customer authority documents, whilst
maintaining required traceability for each component.
a Ordering authority document specified raw material from approved supplier.
a Verifying certified supplied material meets chemical & mechanical properties, and dimensional requirements.
a Liaising with and providing technical support to the production department to create customer approved,
manufacturing plans, specifying exactly how, and what sequence the component is machined/ processed/ handled/
stored/etc. during manufacture.
a Liaising with customer and production department to resolve technical issues.
a Implementation of root cause analysis of defective components.
a Revision of manufacturing plans to eliminate errors determined at root cause analysis.
a Revision of manufacturing plans to reflect technical data revision.
Aug 2005 a Aug 2008
Pratt & Whitney (Commercial Aircraft Engine Overhaul & Repair)
PWAI, Ireland & CHCEC (Christchurch Engine Centre), New Zealand
Position (Ireland): Engine Case Repair Engineer
Position (New Zealand): Process & Methods Engineer
Roles/Responsibilities:
a Certifying repaired/overhauled components as airworthy.
a Implementing new repairs/processes for aviation components.
a Writing of repair processes as per applicable authority documents.
a Liaise with OEM to resolve technical issues, such as the implementation of aextraordinarya repairs (repairs
not yet covered by the OEM repair manual).
a Liaising with customers (commercial airlines) to inform them of the repairs/overhaul required on a
component.
a Providing clear, concise technical support to Commercial & Production departments.
a Root cause investigation & process improvement (Kaizen) events for aproblema areas (process producing high
levels of non-conforming/defective components).
a Review and modification of repair plans, and methods, in line with root cause investigation findings &
Kaizen recommendations.
Mar 2004 a Jul 2005
Roadstone Provinces Ltd., Dublin, Ireland.
Position: Production Engineer
Roles/Responsibilities:
a Review/modification of manufacturing processes to achieve greater efficiency.
a Implementation of ISO 9001 & ISO 14001 (over 3 manufacturing plants).
Sep 2003 a Feb 2004
Fraunhofer CMI, Boston, USA.
Position: Manufacturing Engineer - Internship.
Roles/Responsibilities:
a Investigate manufacturing methods to achieve greater efficiency.
a Developing jigs & fixturing for various projects using Solidworks.
Jun 2000 a Jan 2001
Fujitsu Isotech Ireland
Position: Manufacturing Engineer - Internship
Roles/Responsibilities:
Review/troubleshooting of manufacturing processes achieve greater efficiency
Other Education / Award
Award
Limerick Institute of Technology
a Academic Student of the Year 1999
Sep 2001 a Feb 2002
University of Limerick
a Thermo-Compression Bonding - Feasibility Study (Final Year Project)
Apr 2005
Irish Management Institute
Roadstone Provinces Ltd. Graduate Development Program
Apprenticeship a 4 years (Car Mechanic)
Mar 1996 a
Aug 1997
H.B. Dennis Motor Group, Dublin, Ireland.
a Position: Apprentice Motor Mechanic.
Sep 1993 a
Feb 1996
Sean White Car Sales, Athlone, Co. Roscommon, Ireland.
Position: Apprentice Motor Mechanic.
Other Vacation Work Experience
Jul 2002 a Jul 2003
Coffey Construction Ltd., London, UK.
a Position: Site Foreman & Marking-Out Engineer.
Aug/Sep 2001
Kells Irish Restaurant & Pub, Seattle, USA.
a Position: Waiter
Jun 1999 a Sep 1999
Neil Pearson Carpentry, London, UK.
a Position: Carpenter
Jun 1998 a Sep 1998
Mike Fenwickas Bar & Grill, New York, USA.
a Position: Bar Tender.
Software
a Microsoft Office
a PTC Pro/Engineer
a AutoCAD
a AlphaCAM
a MasterCAM
a SAP
a Solumina
a HMS
a Visiprise
a Tracs (Tooling)
Languages
a Business fluent in English
a Basic French
a Basic German
a Negotiable Irish
Additional Activities
While living at home in Ireland, I coached the local boxing club, of which I joined when I was 9 years old. I have
won numerous county & provincial titles in Ireland, USA, New Zealand & Australia. I have reached an all-Ireland
final, and during my internship in Boston, I won the New England Golden Gloves (7 American States). I continue to
box competitively in Australia.
I also have participated in Gaelic football and hurling from an early age and have represented my club and county.
Other interests include reading and travelling.
Cover Letter:
To whom it may concern,
Please find a covering letter and my resume.
As of 2005, I have been working as an engineer within the aviation industry.
a 3 years with Pratt & Whitney a aircraft engine manufacturers (Ireland and New Zealand).
a 2 years Production Parts Pty, Melbourne a aircraft component manufacturer for the Joint Strike Fighter (both
engine and fuselage components).
a 2.5 years (to present day), with Boeing Aerostructures Australia, on the 787 Program.
During the past 7 years working in the aviation industry, I have gained a broad range of both knowledge and
experience dealing with technical issues in the manufacture, overhaul and repair of equipment from OEMas such as:
a Pratt & Whitney
a Rolls Royce
a IAE (V2500)
a Lockheed Martin
a Northrop Grumman
a GE
a Eurocopter
a Boeing
My initial position in the aviation industry was as Engine-Case Repair Engineer with PWAI (Pratt & Whitney Dublin).
PWAI repair and overhaul engine cases of commercial aircraft for major airlines, mainly in Asia and the USA. The
majority of the cases repaired in PWAI are from Pratt & Whitney PW4000 engines. The remainder are PW2000, JT9D and
IAE V2500 engine cases. My main role at PWAI was to
a Create OEM Engine manual repair/overhaul planning, ensuring that all contractual & regulatory
requirements/obligations were met (and updating of planning post OEM Engine manual revisions).
a Assess the incoming condition of engine cases.
a Produce a shop-routing-card (traveller) specific to each engine case, for each necessary repair.
a Should a potentially defective condition arise, not covered by OEM Engine Manual, I would then generate a
specific repair plan, through communication with the OEM for analysis and approval.
a Assess repaired/overhauled engine cases to ensure that all repairs were carried out per Engine Manual, and
contractual & regulatory requirements/obligations.
a Once contractual & regulatory requirements/obligations are met, I would then certify each case as
flight-worthy, and arrange for each case to be returned to the customer.
a Ensure all records created to repair/overhaul the cases, were retained in an orderly manner.
a Implementation of lean techniques, where lasting improvement and efficiency was necessary.
a Participation in cross-functional teams at Kaizen events, in order to resolve production issues.
After PWAI, I transferred to Pratt & Whitneyas Christchurch Engine Centre (CHCEC) in New Zealand in order to gain
some experience within an engine overhaul facility. CHCEC repair and overhaul IAE V2500, Pratt & Whitney JT8D &
Rolls Royce DART engines - and my position was Process & Methods Engineer, and involved the generating the necessary
planning and documentation for the implementation and qualification of newly introduced V2500 Engine Manual repairs
a the V2500 engine repair and overhaul facility had just been introduced in CHCEC, at that time.
After 3 years with Pratt & Whitney, my next post was within the aviation industry was in Melbourne with Production
Parts Pty Ltd. My job title was Manufacturing Engineer. I was involved in the production of aircraft components of
varying geometry from raw materials, for to a multitude of aircraft, such as the Joint Strike Fighter Jet, for end
customers including Pratt & Whitney, Lockheed Martin, Northrop Grumman, GE, etc. I also project managed the
Eurocopter France contract, from an engineering and production perspective.
As of the 17th of August 2010, I have been working in Boeing Aerostructures Australia (BAA). My initial role was
Manufacturing Quality Engineer (MQE) a Composite fabrication, as part of the 787 program. It was necessary to become
a subject matter expert for every aspect of the resin infusion fabrication process (per HPS 9-001), in order to
provide guidance and support to all involved a This included the retrieval of cure data from the rib ovens should
the primary cure data software fail to produce a report (without cure data, there would be no traceability that the
particular part would have the structural strength necessary for service). During any downtime, I created an
extensive training manual documenting every aspect of the cure buy-off procedure for resin infused parts - for both
experienced and inexperienced MQEas - in order to promote consistency and standardization in the cure buy-off
process.
Within a year of joining BAA, I applied for, and was appointed to my current position of Manufacturing Engineer (ME)
within Composite Fabrication, again, as part of the 787 program. As ME, my key role is as part the Production
Support Group, responsible for preparing planning and conducting qualification activities for both equipment
producing afly-awaya parts, and the afly-awaya parts also.
A major aspect of my current role is project management a one project I am currently working on is the modification
of production ovens (used for the manufacture of resin-infused, fiberglass reinforced, carbon fiber laminate
afly-awaya production parts). This project also includes the modification of all associated tooling (one-sided
moulds - lay-up mandrels, which the carbon-fiber laminate is placed) tooling, which will also be qualified in the
modified oven by carrying out tool-thermal-profile trials.
It is also my responsibility to provide technical input and assessments to activities, such as, design review,
production methodologies and inspection/quality processes.
In order to excel at this position, it was also necessary to personally develop a high level of expertise in every
aspect of manufacturing engineering process, and its application to aircraft component manufacturing.
Education: After high school, I completed a 4-year motor mechanic apprenticeship. I began my college education in
1997. I graduated from Limerick Institute of Technology (LIT) in 1999 with a National Certificate in Manufacturing
Engineering. From there I transferred to the University of Limerick (UL) to complete a BEng Degree in Production
Engineering - I graduated with an honours degree in 2002.
Additional Engineering Related Experience: After a year working in London with the Coffey Construction Company, as a
site foreman and marking-out Engineer, after graduation, I was accepted into the Fraunhofer Institute in Boston,
USA, as an Engineering Intern. The Fraunhofer Institute, affiliated with Boston University, carry out research into
manufacturing systems. My main role was researching diamond cutting tools a or to be more specific, the
investigation in failure point of diamond cutting tools. This also involved developing jigs & fixturing for various
projects using Solidworks.
Upon my return to Ireland from Boston, I began work with Roadstone Provinces Ltd., a building materials company, in
the role of Production Engineer. My initial placement was in a concrete roof tile manufacturing plant in Dublin.
Responsibilities/roles within Roadstone included: Quality Controller, Plant Supervisor, Implementing ISO 9001
(Quality Management System), Implementing ISO 14001 (Environmental Management System), Setting up a preventative
maintenance program, Reorganising the stores system.
My Resume below lists my main roles in the different positions I have worked, up to present day. Feel free to
contact me if you have any questions or require further documentation, such as reference letters, referee contact
phone numbers, exam results, etc. I look forward to your reply.
Yours Sincerely
Sean Egan
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