Steve FitzGerald

Email: abqi1a@r.postjobfree.com

Address: **** ** ***** **.

City: Wichita

State: KS

Zip: 67010

Country: USA

Phone: 316-***-****

Skill Level: Experienced

Salary Range: $100,000

Willing to Relocate

Primary Skills/Experience:

See Resume

Educational Background:

See Resume

Job History / Details:

Steve FitzGerald

4853 S.W. 100th St.

Augusta, KS 67010

316-***-****

abqi1a@r.postjobfree.com

SUMMARY

Dedicated and detailed, engineer with 20+ years` experience in the aerospace composite industry. Expertise

in aerospace composite manufacturing, lean improvement, and operational support. Proven success leading

large-scale projects from start to finish, within budget, quality, and schedule constraints.

Skilled in root cause problem solving, and computer applications such as: Office, CATIA V5,

Enovia, DelmiaV5, Velocity, Solumina, Teleview, SAP, and various MRP programs.

SKILLS

Composite Manufacturing

* Estimating Aerospace

* Production Planning

* Material Resource Planning

Contract Negotiations

* Procurement

* Process Improvements

* Design for Manufacturing

* RTM/VARTM

* Make/Buy

CAREER ACCOMPLISHMENTS:

Developed manufacturing programs to address root cause solutions, resource planning, tooling, and training

to reduced backlog of 600 parts to 100% on-time delivery in a 10 month period.

Worked in tandem with senior staff to maximize profits and delivery schedules, minimizing work in process,

and managing offload programs.

Composite part and assembly programs have included landing gear struts for the Predator UAV made from carbon

and glass fibers with epoxy resin, utilizing VARTUM process with a proprietary lost wax core process along

with several ducts, aerodynamic skins and fuel panels fabricated using aramid fiberglass prepreg and autoclave cures.

Implemented a process improvement on a deteriorating project, leading to a significant improvement in profit margin,

and created new business opportunities while freeing autoclave capacity.

Manufacturing Engineering lead for environmental control systems and aircraft interiors programs for the Premier 1

business aircraft. Project manager and contract negotiator for mult-million-dollar PCXII interior program.

PROFESSIONAL EXPERIENCE

Manufacturing Engineer

Park Aerospace Technologies Corp. Newton, KS June 2011 - Oct 2012

Park is a startup job shop who just started to build parts using process ovens and autoclaves.

They also make pre-preg on using carbon, fiberglass, Kevlar and quarts fabrics or tow and primarily epoxy resins

for multiple aerospace customers.

Responsible for the development of Statement of work (SOW`s), and new business requests for the composite manufacturing side.

Created manufacturing bill of materials, operational sequence, labor estimates, testing requirements, tooling required,

and lead-time needed to get everything ordered, tools fabricated, parts produced, tested and assembled and cost of all

into a quotation response with the desired profit margin.

Traveled to AAR in Clearwater Florida to assist them in a warpage problem they were having with some panel

which used PARK composite prepreg on both sides of the sandwich panels they were producing at that location.

I was able to determine the problem and had them back on track running flat honeycomb core composite panels in 24 hours.

Process Engineer

Sikorsky, Troy, AL Feb 2010 - June 2011

Processing Engineer for the MH-60R Navy helicopter major structure joining the upper, lower, landing gear, and canopy sections.

Provided shop floor support for planning, tooling, and drawing and specification interpretation.

Worked with MRB, Quality, Manufacturing leads and Engineering to resolve out of tolerance conditions.

Interfaced with their composite manufacturing subcontractor, GKN, to expedite a canopy which was jeopardizing an effectively

part roll. Requested and received special composite drill bits to eliminate the fuzzy holes in the Kevlar honeycomb fuel panels

and other Kevlar parts which can be difficult to drill without the right bits.

Manufacturing Engineer

Boeing, Everett, WA 2009

Manufacturing Engineer for 787 Final assembly and delivery.

Created and revised installation packages for modules on the 11 & 45 sections.

Worked technical issues within a MBD environment utilizing Enova and CATIA V5.

Evaluated in and out of sequence modules on wing to body section for assembly integration between partners

and internal departments to validate engineering updates and configuration management.

Provided repair plans to composite parts on the aircraft that had been damaged in assembly.

Manufacturing Engineer

Fiber Dynamics, Inc., Wichita, KS 2007-2009

Manufacturing Engineer, specializing in RTM, VARTM, and lost core composites.

Coordinated and estimated first major composite assembly program for the Cessna`s CJ4 entry step.

Responded to RFQ`s to provide SOW`s concepts, assembly breakdowns, materials, labor hours, testing and inspection

and other requirements.

Provided shop floor support for all composite fabrication areas mold preparation, layup, trim, 3- axis foam core

fabrication, paint, ovens, presses, resin mixing, inspection, MRB, part mark, and shipping. Provided step by step

composite manufacturing planning for all new projects and some of the older parts that we had trouble getting in the past.

This included the material type (lightning strike, carbon, veil 120 fiberglass and, fiberglass, tactifier solution,

resin and bagging materials).

Placement of composite materials, warp direction, sucker location, and vacuum test procedure.

Also, mold prep, oven cure cycle, finishes, part mark locations and any other information needed.

Work instructions were written in PowerPoint split screen with instructions on the left and pictures/drawings on the right.

Program Manager

TECT Aerospace, Wichita, KS 2006-2007

Achieved project milestones by managing communications between stakeholders and customers, and generating, collecting, storing, and

disseminating critical project information.

Provided corrective actions, determine root cause, and initiated process deviations to eliminate scrap.

Continuously worked toward just-in-time deliveries, inventory reduction in raw materials, work in process, and finished goods.

Although TECT was primarily a metal machine, assembly, and welding house I was able to pick-up valuable program management experience.

Involved in a lean six sigma process improvement to reduce long term stocking of parts substantially reducing corporate taxes.

Sales Engineerenior Aerospace Composites, Wichita, KS 2005

Composite products estimator and manufacturing engineer for the aerospace industry.

Provided quotes to customers including pricing, lead time, and scheduled deliveries.

Increased productivity using older proven and leading-edge composite materials and manufacturing methods.

Created ideas to improve yield and reduce autoclave load runs by -stacking- for some Cessna aft partitions which Engineering revised

for weight reduction. Method actually improved the quality of the composite sandwich parts by getting a hard surface on both sides of

the panels.

CONTRACTOR- QUALITY, TECHNICAL PERFORMANCE

Grumman Corp., Integrated Systems, Wichita, KS 2004-2005

Monitored program visibility for program visibility for aerospace and military platforms for the U.S. Armed Forces in the Kansas area.

Conducted post contract award surveys to ensure suppliers understood purchase order requirements, and verified that manufacturing cycle

plans supported project critical path dates.Made frequent trips to subcontractors facilities to obtain load dates for parts and

assemblies which showing running very close to schedule or that could miss a load date causing significant delays and out of position

installations.

Senior Manufacturing Engineer

Raytheon Aircraft Company, Wichita, KS (now Hawker-Beechcraft) 1995-2003

Lead SR. Manufacturing Engineer supporting interior and ECS IPT teams on the Premier I aircraft.

This aircraft was the first new clean sheet program for an aircraft since the starship 30 years earlier.

Nearly every part had new drawings for detail, assembly and Installation.

Provided producibility for all Interior and ECS team drawings

Supported engineering groups for design changes, materials, and processing capabilities.

Determined optional methods, materials, and processes to reduce weight, cost, and installation requirements.

Provided coordination data between plastics, composites, upholstery, vendors, ECS, interior installation and management.

Approximately 90% of the parts I had Manufacturing authority over were made from thermoset composites.

Most were designed from thin, low density foam core and epoxy fiberglass prepreg while others were thermoformed from Kydex plastic sheet.

Underwent a major design change late in the process to reinforce the cabin around the cabin door and remove approximately seven pounds

effecting 168 drawings from hydraulic tubing wall thickness to the weight of the Honeycomb core material.

Working with Rapid PSI (a 3D prototype company in Wichita), we were able to cast from plastic and subsequently using a proprietary

surface preparation, we were able to match the seven available finishes for the customer options list.

This effort saved two pounds per aircraft on six cup holders in the ship set.

Although the effectively was stopped at RB-99, it was very useful in getting out certification by meeting maximum plane weight

in the FAR23.853 class.

Project Manager

Creative Interiors Inc., Wichita, KS 1991-1994

Coordinated with a design firm in the selection of materials, fabrication methods, and review of engineering drawing package

to ensure parts and assemblies could be feasibly produced.

Co-managed an intensive, six-week effort to mock-up the interior of the Lear 45 aircraft on display at the 1992 NBAA show in Dallas.

Some of the composite programs I worked on were the Boeing Nacelle core cutting templates, the Pilatus PCXII Interior, sidewalls,

cabin headliner, toilet riser and other furniture including the refreshment cabinet, tables, partitions and many more.

EDUCATION

Bachelor of Arts - Industrial Technology

Wichita State University, Wichita, KS

Boeing, Everett, Washington, 2009

Velocity, (TR011375, TR010099, TR010434, TR011866)

ENOVIA V5 Essentials (TR008737), and DELMIA V5 Process Engineer (TR001130).

CATIA V5 Basic Concepts and Operation. (TR001112)

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