Engineer Quality

STEPHAN G. CASSEL

** *. ****** ***. ***. # *

Pasadena, CA 91106

Cell: 626-***-****

Email: **********@*****.***

AVIATION QUALITY ASSURANCE INTERNAL LEAD AUDITOR

PROFESSIONAL OBJECTIVE:

A highly accomplished and skilled professional with extensive experiences as a AVIATION

QUALITYASSURNACE INTERNAL LEAD AUDITOR, with expertise in competitive technical and

team management and the distinguished ability to conduct accurate needs analysis, solve problems, assess

technical capabilities, build and motivate teams, conduct strategic planning and manage products in a

company where my extensive experience and skills can be best utilized, and have growth possibilities.

QUALIFICATIONS:

30+ years Management experience providing the leadership necessary for Quality strategies to

achieve or exceed business objectives and to develop, deploy, and manage an effective and efficient

Quality System.

• Have worked for the following Aerospace Production OEM Manufacturer – McDonnell

Douglas/Boeing and have had the following Aerospace Production OEM Manufacturers for

customers; Airbus, Boeing, Gulfstream, Bombardier, Cessna, Lear Jet, GE Engines, Pratt & Whitney,

Rolls Royce, Honeywell, and many others.

• Reviews regulatory, program and, Customer requirements ensuring early quality involvement in

program development.

• Have approximately 10+ years supervising/managing Quality Engineers and Inspection Teams.

• Working knowledge of ISO 9000, ISO 9001:2008, AS9100 Rev. “B” and recent training to Rev. “C”,

First Article Inspection (First Article Inspection Reports(FAIR per AS9102), NADCAP (Special

Processes), MRB (Material Review Board), Internal Auditing, Root Cause & Corrective Actions).

• Excellent personnel and presentation skills to interact directly with both internal and external

customers.

• Assures Supplier understanding of product.

• Review and approve Supplier quality plans on new and existing programs.

• Reviews and approves Supplier manufacturing processes and quality systems.

• Maintains Approved Supplier Listing (ASL).

• Initiate or revise quality assurance procedures applicable to subcontracting practices.

• Determine root cause of supplier quality and coordinate/implement effective and timely resolution.

• Maintains supplier ratings or scorecards and distributes to suppliers at pre-determined intervals.

• Improve quality performance of suppliers by conducting workshops at supplier locations; provide

technical assistance in developing quality systems, and other technical support as required.

• Develop, implement and maintain detail audit schedules and subsequent surveillance activities.

• Initiate and follow-up on supplier corrective action requests.

• Knowledgeable with Federal Aviation Administration (FAA), Federal Aviation Regulations (FAR Part

21), FAA-Manufacturing Inspection District Office (MIDO) and, was an FAA-DMIR (Designated

Manufacturing Inspection Representative) for McDonnell Douglas/Boeing in Europe and the Middle

East and Long Beach, Ca. for 6 years.

• Very familiar with High Volume Environments including Composite Manufacturing and Inspection.

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• Familiar with Lean, Six Sigma, Problem Solving Techniques, and both Visual and Dimensional

Inspection.

• Excellent Technical Writer.

• Familiar with Statistical Process Control (SPC), quality plans, inspection standards, blueprint reading

and sampling plans.

• Responsible for a wide variety of quality functions associated with the procurement and/manufacture

of aerospace parts and assemblies including Composites to customers requirements.

• Proven aircraft experience, and experienced with implementing and improving various quality

systems, an “A” player that will be the face for the Quality on programs, and experienced in the

transitioning from development programs to production.

• Perform system, product, process, and surveillance Audits IAW AS9100 audits schedule.

• Participates in Supplier Audits/Surveys in support of Purchasing.

• Assist in the development and implementation of Supplier Performance Metrics and initiates Quality

Improvement initiatives with Suppliers as necessary.

• Experienced in support of Machine Shop/manufacturing operations and processes including

Composites..

• Provides technical expertise to company employees, suppliers, customers, and Regulatory agencies to

assure compliance of procured products to dimensional, contractual, company, and Regulatory

requirements.

• Works effectively in a cross - functional Team environment and has the abilities to work on several

projects/tasks simultaneously.

• Excellent teamwork skills.

• Ability to develop and execute action plans which achieve company goals.

• Excellent oral and written communication skills.

• Decision making ability and creative problem solving skills.

• Customer oriented focus with a creative, aggressive and winning attitude.

• Reduced Cycle Times and Return to Vendor (Supplier) processing times for significant Company

Cost Savings.

• Participated in many Vendor/Supplier Quality Audits both Domestic and Internationally including

C.A.S.E. and Delta Airlines Audits with highly successful results.

• Participated in many FAA ACSEP Audits both Domestic and Internationally.

• Technical: U.S. Marine Corps certified with 20+ years experience in Aviation Electronics.

• FAA-DMIR (Designated Manufacturing Inspection Representative) - Currently INACTIVE.

• QA Manager / Chief Inspector for FAA Part 145 Repair Station # A13230N and FAA PMA Facility.

SKILLS:

• PC: MS Word, Excel, Powerpoint, Access, MS Outlook, MS Exchange, Long Beach Task Card

Authoring System, EMOD (Electronic Maintenance and Operating Data), Aero Info (Maintstream).

• Quality: SPC, Corrective Action, ISO9000, ISO9001, AS9100 Registered, Boeing Quality

Management System (BQMS), TQMS, PBM, Boeing D1-4426, Mil-Q-9858, MIL-I-45208, MIL-C-

45662 and MIL-STD-105, TQM.

• Auditing: AQS-Auditor D1-9000, Successful Completion of RABQSA Accredited Certified AS9100

Rev. “B” and recent Rev. “C” Aerospace Quality Management System training Lead Auditor Course -

April 2010.

• Experience with Lean Manufacturing and Six Sigma processes.

• Finance: Cost Account Manager.

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• People: Diversity & Cultural Characteristics Training.

• Organization: Integrated Program Team (IPT) Leader, Self-Directed Work Teams, CAB’s, MRB,

CRB, SCAR’s, SCAN’s, NOR’s and Lean Manufacturing.

SKILL/KNOWLEDGE AREAS:

Quality Engineering - Commercial/Military A/C Products

• Strong Customer relationship experience, strong people skills (negotiation, presentations, and cross

department team building.

• Conduct Functional Configuration Audits / First Article Inspection with customers on program related

issues.

• Act as a consultant to provide extensive expertise to a variety of technical, business and/or

programmatic quality issues.

• Assures that Customer quality-imposed requirements are adhered to by the supplier and that a

Quality System is maintained.

• Performs Vendor performance analysis and quality audit program. Takes an active role in the

management of current supplier, and provides supplier engineering support to operations, and drives

supplier quality improvement at supplier sites.

• Act as liaison to internal customers in resolution of problems affecting quality standards.

• Reviews and analyzes Corrective Action Reports and Purchase Orders in an effort to reduce and

eliminate defects by continuous improvement.

• Applies Quality System expertise in resolving strategic product, process, and business issues.

• Evaluate and accept/reject Supplier corrective action responses that address Supplier deficiencies and

verify corrective action implementation.

• Inspect and/or verify products in accordance with contract/purchase order requirements utilizing

approved methods (for example; witness acceptance test procedures (ATP), perform/verify First

Article Inspections (FAI), etc.) for acceptance.

• Assist suppliers in Continuous Improvement of Products/Processes by utilizing Process Validation

Assessments (PVA) on specific hardware to substantiate supplier’s adherence to processes,

procedures, and specifications.

• Performs Quality Engineering review of engineering documentation and processes to assure that

quality metrics are identified, appropriate and measurable.

FAA Designated Mfg. Inspection Representative (DMIR) Management (Europe & Middle East)

• Act on behalf of and as a designee of the FAA to oversee and ensure compliance to the Quality

System.

• Apply extensive regulatory knowledge and technical expertise to the development of solutions to

complex problems.

• Conduct inspections of materials, parts and assemblies in original production or modified from

original type design products to ensure that they conform to type certification or engineering

approved data and pass inspection for safe operation.

• Mediate and direct the resolution of conflicts and concerns among FAA, company, customers and

suppliers.

• Provide technical expertise to company employees, FAA, customers, and suppliers on issues of

compliance with contractual, Regulatory, and company requirements.

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• FAA Composite and Process Conformities at Fischer Advanced Composites Corporation (FACC) in

Reid, Austria and Toledo, Spain.

EXPERIENCE:

SIKORSKY GLOBAL HELICOPTERS – COATESVILLE, Pa. DECEMBER 2012 TO MARCH

2013

QUALITY ASSURANCE INTERNAL LEAD AUDITOR

DEVELOP AND EXECUTE AN ENTERPRISE INTERNAL AUDIT PLAN THAT

CONTINUALLY ASSESSES AND CONFIRMS COMPLIANCE TO CFR21, CFR145, PMA, ODA

AND AS9100, REV. C AS WELL AS INTERCOMPANY PROCEDURES AND WORK

INSTRUCTIONS, THIS ALSO INCLUDES THE MANAGEMENT OF CLIENT’S

CORRECTIVE / PREVENTATIVE ACTION PROCESSES.

SYNCHRONOUS AEROSPACE GROUP STRATOFLIGHT = SEPTEMBER 2012 TO

DECEMBER 2012.

SENIOR QUALITY ENGINEER

Alenia 787 Program First Article Inspection Report creation for Seat Track Top Assemblies, Sub-

Assemblies and Detail Parts Submittal to ALENIA COMPOSITES –GROTTAGLIE, ITALY

REGENT AEROSPACE CORP. – VALENCIA, CA. JUNE 2012 TO AUGUST 2012

QUALITY ASSURANCE MANAGER FOR FAA REPAIR STATION #PA8R131J IN SINGAPORE

which modified NorthWest Airlines (NWA) Boeing 747-400 Passenger Airplane Interiors to the

DELTA Airline Colors, Livery and Interior Decor Including Sidewall Panels, Lavatories, Galleys,

Crew Rest Areas and Stairwell Panels and Flight Deck Door in Singapore to Incorporate the Delta

Airlines Scope of Work and the Delta Airlines Interior Configurations.

While working with Delta Airlines and SASCO (SINGAPORE AEROSPACE COMPANY) at ST

Aerospace on Singapore Air Force Base.

AAR COMPOSITES - SACRAMENTO, CA. FEBRUARY 2012 TO APRIL 2012.

SENIOR QUALITY ENGINEER – BOMBARDIER, LOCKHEED MARTIN F-35, AND BOEING

SPIRIT 747-8 PROGRAMS.

First Article Inspections and submittal to the Various Customers for Shipment and Acceptance of

Products, Assemblies and Sub-Assemblies. Contract Review, Purchase Order Review, submittal of

Non-Conformance Products to the various Customers. Composite parts, sub-assemblies and

assemblies inspection.

MARVIN ENGINEERING – INGLEWOOD, CA. NOVEMBER 2011 TO FEBRUARY 2012.

Senior Quality Engineer – various Commercial and Military Programs.

Various Missile Launchers, Bomb Racks, and Line Replaceable Units for both Aircraft and

Helicopters. First Article Inspections and submittal to the Various Customers for Shipment and

Acceptance of Products, Assemblies and Sub-Assemblies. Contract Review, Purchase Order

Review, submittal of Products to the Government DCMA Representatives.

DUCOMMUN AEROSTRUCTURES INC. – MONROVIA, CA. MAY 2011 TO SEPT. 2011

Senior Quality Engineer – EMBRAER PROGRAM COMPOSITES

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Ailerons, Spoilers, Tail Cone, Emergency Over wing Exit Door, Hatch Door, Cargo / Baggage Door

Material Review Board, Detail and Assembly Inspections, Planning Review, and Process Validations

for Prototype / Development Program for the EMBRAER Legasy 500 Program.

I was also supporting the Bell Helicopter Main and Tail Rotor Program, Boeing 737 Spoilers,

Boeing 767 Main Cargo Door, Boeing 777 Horizontal and Vertical Assemblies, Apache and Sikorsky

Program Main and Tail Rotor Blade manufacture.

HITCO CARBON COMPOSITES – GARDENA, CA. JUNE 2010 TO MARCH 2011.

Senior Quality Engineer for the Alenia, Italy / Boeing 787 Program Material Review Board,

Rejection submittals to the Customer and Inspection of composite parts and assemblies.

SENIOR QUALITY ENGINEER FOR THE ALENIA, ITALY BOEING 787 PROGRAM.

Verify Inc. (Vendor Surveillance Corporation) Irvine, CA. December 2008 to June 2010.

Source Inspection / Project Specialist for Boeing 787 Program support in Grottaglie, Italy and Charleston,

South Carolina to help Boeing Commercial Airplane (BCA) inspect detail parts, sub-assemblies, and

Major Fuselage Sections 44 and 46 at Alenia Composites.

Crane Aerospace & Electronics (Hydro-Aire & P.L. Porter), Burbank, CA. Nov. 2007 to Dec. 2008.

2 Senior Quality Engineer for the Hydraulic Valves, Pumps and Transducers Product Lines

3 Software Quality Engineer III (DO-178B) (DO-254) Boeing 787 Program, Boeing

737NG Program, Airbus A-400M Program, Aermacchi M-346 Program, and Lockheed Martin

JSF Program.

4 McDonnell Douglas / Boeing - St. Louis – F-15C Program

GKN Aerospace–Transparency Division, Garden Grove, CA. July 2007 to November 2007.

• Senior Quality Engineer

• McDonnell Douglas / Boeing - St. Louis – F-15C Framing Product Line

Alcoa Fastening Systems, Torrance, CA. June 2005 to July 2007

• Senior Quality Engineer

• BOEING 787 PROGRAM – GE AND ROLLS ROYCE ENGINES

• ROHR / GOODRICH AEROSPACE – GE AND ROLLS ROYCE ENGINES

Monogram Systems, Carson, CA. February 2005 to June 2005.

• A380 / Boeing 787 Aircraft Maintenance Engineer

Vendor Surveillance Corporation, Irvine, CA. August 2004 to February 2005.

• Quality Field Specialist and DSQR for Sikorsky.

AirWorks, Inc. Rancho Santa Margarita, CA. July 2003 to January 2004.

• QA Manager / Chief Inspector for FAA Part 145 Repair Station A13R230N and FAA PMA

Facility.

The Boeing Company, Long Beach, CA. March 1988 to July 2003

• Technical Specialist – Product Support

• FAA Designated Manufacturing Inspection Representative (DMIR)

• Senior Quality Engineer/Principal Specialist Quality Engineer

• Section Manager/Group Leader

General Dynamics Services Company, Forth Worth, TX, Oct. 86- Oct 88

• Senior Aircraft Systems Specialist

U.S. Marines, Tech Supervisor, Communication/Navigation/Radar Sys, Oct. 1968 – Sept.1985

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EDUCATION & SPECIAL TRAINING

• B.S. Business Administration, University of Phoenix, Fountain Valley, CA, In Process (Approx. 105

C.E.U.’s)

• A.A. Candidate - Electronics, Arizona Western College, Yuma, AZ, Sept. 1977 – June 1979

• A.A. Candidate - Business Administration, Wisconsin State University, Sept. 1966 – June 1968

• Non-Conformance D Training (Military)

AMERICAN SOCIETY FOR QUALITY (ASQ) MEMBER

• I will be taking the ASQ - CQA (Certified Quality Auditor) and the ASQ - CQM-OE (Certified

Quality Manager – Operational Excellence Exam this year.

• SECURITY CLEARANCES:

• Confidential, 1988 – 2003, Secret, 1968 – 1986

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