Engineer Manufacturing

Brian McCarthy **** Tourmaline Way Rescue, CA ****2

530-***-**** ac12et@r.postjobfree.com

MANUFACTURING ENGINEER

Highly qualified Aerospace/Manufacturing Engineer with 25+ years of experience leading projects from concept through production. Outstanding communicator with capacity to collaborate with Systems and Design Engineers on detailed projects and translate data to Assemblers and Technicians for execution. Natural leader with talent for motivating high performing teams and facilitating employee development through focused training and mentoring. Life-long learner who is motivated by challenges and opportunities to solve problems. Accustomed to managing multiple, changing priorities against critical deadlines. Unmistakable professional integrity, unparalleled work ethic, and commitment to excellence. Secret Security Clearance

Areas of Expertise:

Composite Manufacturing

Process

First Article Assemblies (FAB) Spacecraft Dynamics/Maneuvers

Root Cause Analysis Manufacturing Documentation Modeling/Prototyping

Technical Material Development Quality Control Engineering Flight Mission Control

Machining Drawing Review/Approval Engineering Change Orders (ECOs)

Training/Mentoring Spacecraft Telemetry Analysis Team-Building/Leadership SELECTED CAREER HIGHLIGHTS

Implemented a Kaizen Lean Manufacturing workflow at Alpha Research and Technology which significantly increased productivity resulting in faster delivery times and reductions in delays and errors.

Developed workmanship standards and first article build (FAB) procedures to produce product for rapid production.

Researched, developed, and created Alpha Research and Technology’s first off-site machine shop in compliance with OSHA safety requirements. Conducted cost analysis, created budget, and procured equipment.

Incorporated hundreds of redlines to technical documentations resulting in improved procedures which allowed Alpha Research and Technology to grow from a $6M to a $30M company.

Developed program and trained staff on first CNC machine and 3D printer used to develop prototypes, resulting in increased production for time-sensitive projects with tight deadlines.

At Loral Space and Communications, received recognition and commendation for building newly designed satellites from blueprints. Developed team and processes to manufacture satellite in concert with international colleagues and partners, including RF and Electrical Engineers and space program managers.

Selected to travel to Alcatel Aerospace in Toulouse, France to assist with critical repairs and tasks during launch base assignments. Able to identify problems with satellites in orbit, preventing major transmission issues and potential disastrous accidents.

Traveled to Kourou, French Guiana (European Space Agency); Cape Canaveral, Florida; Baikonur Cosmodrome, Kazakhstan (Russian Space Launch Facility); and Tanegashima, Japan (Japanese Space Development Facility) for delivery, final assembly, test, fuel, and final launch operations. PROFESSIONAL EXPERIENCE

Alpha Research and Technology, Inc. El Dorado Hills, CA 2008 – 3/2017 Senior Manufacturing Engineer

Lead engineering team in manufacturing for both electrical and mechanical processes for critical military projects. Oversee design, machining, and material development to produce customary and proprietary systems for Department of Defense (DOD) contracts. Implement Kaizen Lean Manufacturing practices to improve work processes. Calculate production material/labor costs, review production schedules, and estimate future requirements to inform manufacturing decisions.

Brian M. McCarthy 2

Senior Manufacturing Engineer Alpha Research & Technology (Continued) Collect, analyze, and summarize data/trends to prepare product and process reports. Improve documentation/drawing issues by using redline drawings and creating improved instructions and procedures. Innovate solutions to process problems for non-conforming material (NCR), corrective actions report (CAR), and engineering correction request (ECR). Provide input and budget recommendations for manufacturing plan procedures and qualifications support. Developed and innovated composite manufacturing processes for production of Department of Defense aircraft rack and electrical box technologies. Loral Space and Communications, LTD. El Dorado Hills & Palo Alto, CA 1990 – 2008 Mechanical Vehicle Engineer 2006 – 2008

Produced top assembly sequence instructions (ASIs), RWKOs, and NCRs for spacecraft integration. Provided effective and organized daily task plan for the floor process and printing. Directed the EA and Technician team in support of the Spacecraft Managers goals and objectives. Provided guidance and skilled engineering direction to the technician and program team in accordance with the Spacecraft Managers schedules. Produced and managed production databases. Managed flight and non-flight equipment as needed for spacecraft assembly. Performed critical operations pertaining to spacecraft design and overflow. Troubleshot mechanical issues and provided solutions to increase productivity. Reviewed and approved drawings. Reviewed and incorporated design changes and engineering change orders (ECOs). Space Systems Engineer 2004 – 2006

Served as Payload, Thermal, and Mechanical Support Engineer for spacecraft long-term operations. Conducted spacecraft telemetry analysis and state-of-health assessment. As Dynamic Spacecraft Simulator Engineer, maintained spacecraft simulator for verification of command flight plans, procedures, and training. Ensured safety protocols with spacecraft operations. Developed and established new training processes. Implemented contingency real-time drill operations to increase productivity and safety procedures. Coordinated and prepared presentations and semi-annual/monthly reports for Loral customers, providing timely statistics and recommendations for resolution of spacecraft anomaly issues. Lead Flight Controller Engineer 2001 – 2004

Oversaw control room shift operations. Monitored complex, multiple spacecraft dynamics and maneuvers using “ITACS” and “TAPS” commanding and monitoring systems. Prepared anomaly reports for customers to improve performance and trending analysis decisions. Developed and established new training processes. Implemented contingency drills. Improved team performance and safety procedures. Selected as Lead to interpret problems with telemetry and spacecraft issues. Lead Manufacturing Technical Engineer 1990 – 2001 Oversaw spacecraft top assembly, performance, and pre-flight testing operations. Maintained and interpreted complex engineering blueprints and designs. Modeled plans through skilled definition and prototype objects prior to implementation on actual spacecraft. Managed individual spacecraft mechanical teams, providing leadership and job training. Monitored quality control during and after testing performance. Oversaw quality delegate (QD) and quality control conformance procedures. EDUCATION PROFESSIONAL DEVELOPMENT

City College of San Francisco San Francisco, CA

Associate of Science FAA Certification – Avionics Airframe and Power-Plant Associate of Science – Fire Science

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