PROFESSIONAL QUALIFICATIONS

Program Manager: Bring extensive functional, project, supplier, change and program management experience to the team. Have a proven track record in building efficient teams, working in multi-functional (IPT) environment and developing collaborative customer relationships. Possess strong leadership, conflict resolution, problem solving, communication (written and verbal), multi-tasking and interpersonal skills. Have developed and managed program processes and procedures. Developed SOWs, WBSs, Project Management Plans, Integrated Master Schedules and Risk Management Plans. Was Affordability SME for C-17 Program. Mentored junior engineers in aircraft structural design while on C-17 program and at Eaton.

PROFESSIONAL EXPERIENCE

GKN Aerospace, Santa Ana, CA 8/2015 to present

Program Manager Airbus A-350-1000 Exhaust Acoustic Panels

Managed production of engineering development and flight test units

Led production of over 1,000 test coupons for flight test qualification and aircraft type certification programs

Held full P&L responsibility for $1.4M production development and $2.2M production of test program coupons

Developed project plans and schedules for nine test coupon production projects

Led IPT consisting of operations teams, ME, QE, QA, tooling, planning, contracts and supply chain

Managed recovery of late to delivery military aircraft product program

Esterline NMC, Pomona, CA 5/2014 to 12/2014

Project Manager (contract position through Artemis Search Partners)

Managed projects for manufacture of injection molded Nylon, PEEK and ULTEM ™ parts.

Led development, qualification and transition to production of new lightning protection parts for Airbus A350.

Introduced design change to enable design to meet customer’s mechanical testing requirements

Led creation of new production cell to meet customer requirements

Managed first part qualification of fuel system clamps for Boeing 787

Analyzed current product costs to support price negotiations with customer

Assisted QA Manager in overhaul of all current procedures

Eaton, Irvine, CA 10/2013 to 2/2014

Program Manager II (contract position through APR)

Managed Boeing KC-46A Tanker Fuel System new product development program.

Led recovery of procurement schedule delay caused by material and processing changes to ~ 300 parts.

Developed detailed schedules for procurement, supplier and internal fabrication and processing, assembly and testing of the eight systems being designed and produced for the tanker program.

Planned and executed assembly, testing and FAA conformity of Boom Nozzle system.

Zodiac Aerospace, Galley Inserts, Carson, CA 8/2012 to 1/2013

Program Manager

Managed portfolio of product improvement and new product development programs for commercial aircraft O.E.M.s.

Ran development of new air and beverage chillers for Bombardier Global 7000/8000 aircraft.

Led implementation (including certification) of trash compactor design changes for Airbus A380 and Boeing 737, 747, 757 and 787 aircraft.

Boeing Commercial Aircraft, Santa Ana, CA 3/2012 to 8/2012

787 Program, Boeing/Coast Recovery Team

Senior Project Manager (contract position through VTR)

Provided Supplier Oversight of fabrication composite tooling for 787 Aft Fuselage at Coast Composites (Anaheim facility) and Composite Horizons (Covina facility).

Maintained daily work in process (WIP) status charts and program schedule updates for assigned sites.

Coordinated resolution of material shortages, discrepancy dispositions and engineering design change flow down with Boeing Commercial Airplanes, Boeing South Carolina and Supplier components.

Managed hand-off of 3200 task MS Project master schedule to supplier focal.

Boeing Defense Systems (Legacy McDonnell Douglas), Long Beach, CA 6/1986 to 10/2011

C-17 Military Transport Program

Senior Project Manager, Program Management: 7/2009 to 10/2011

Managed projects for Program Management, Supplier Management and Engineering IPT.

Led development of Requests for Proposal (RFP) and Selection Criteria for re-bid of four Tier One Supplier composite structure work packages (acting Supplier Program Manager).

Directed development of Data Protection and supported development of Disposition of Production Tooling sections of Post Production Transition Plan proposal for USAF.

Managed technical and business feasibility analysis of over 300 supplier affordability proposals.

Led projects to replace worn Boeing Furnished Tooling used by four Tier One Suppliers.

Manager, C-17 Change Management: 7/2005 to 7/2009

Led group of 14 change analysts managing configuration change approval and implementation process. Facilitated three weekly program Configuration Control (Change) boards.

Ran annual process improvement in conjunction with the Air Force.

Participated in pricing and estimating of all Performance Enhancement Product Improvement (PEPI) and Global Sustainment Partnership (GSP) projects.

Managed three (3) cost accounts using Boeing EVM procedures

Introduced cross training which enabled 29% budget reduction over 3 years.

Managed Change Process (Boeing Best Practice and CMMI 5) which spanned project initiation through closure.

Project Manager, C-17 Airframe & Mission Systems: 4/1998 to 7/2005

Led projects ranging from replacement of worn supplier tooling to redesign of primary structure.

Recovered 4-month schedule slip on monolithic emergency egress door and prevented significant aircraft delivery delay. (Assumed leadership during development phase.) Led effort to transfer fabrication from non-performing supplier. Prevented delivery delay of seven aircraft.

Managed replacement of non-compliant material on delivered aircraft and root cause corrective action for supplier quality escape.

Led projects to replace worn Boeing Furnished Tooling used at nine Tier One Suppliers (US and Foreign) and evaluation of Main Landing Gear Door Ply Lay Up and Assembly tooling for replace or continue repair decision.

Participated in transfer of forming 96 skin panels from Long Beach site to a major subcontractor.

Selected as one of the nine person team that developed and deployed C17 project and change management processes and procedures based on SDLC process and PMI best practices.

Manager, C-17 Fuselage Automation and Drawing Compliance: 9/1997 to 4/1998

Directed group of 20 engineers in schedule recovery of project to build 3-D models of fuselage skin panels to support automation of skin panel assembly process.

Managed 10 person fuselage drawing check group.

Project Manager, C-17 Fuselage Special Projects: 1/1997 to 9/1997

Represented Fuselage group at Front Line (Major Join, Final Assembly and Flight Ramp), Center Fuselage and Forward/Aft Fuselage Integrated Product Teams (IPT) in effort to reduce age of engineering corrective actions.

Manager, C-17 Aft Fuselage Design: 10/1992 to 1/1997

Directed a group of 12 engineers responsible for design of aft fuselage. Supported static test and durability test. Represented Airframe, Aircraft Systems and Mission Systems engineering at Aft Fuselage IPT.

Led redesign of complex skin panel assembly for $11M savings over life of program.

Supported Static and Durability testing of airframe. Authorized for MRB for test articles.

Eliminated over 2000 hours of rework and repair per aircraft through use of Design for Manufacture and Assembly (DFMA) principles.

Engineer & Senior Engineer, C-17 Aft Fuselage Design: 6/1986 to 10/1992

Led a team of 12 to 30 in design of Aft Fuselage Structure.

Supported production of first aft fuselage assembly though one-year co-location to production area.

Managed redesign of cargo door actuator system to allow the fuselage to pass proof pressure test program milestone. Introduced the first monolithic machined part on C-17 fuselage.

Led redesign of cargo door down lock to complete in-flight closure of cargo door program milestone.

Midland Standard, Elgin IL 5/1984 to 6/1986

Manufacturing Manager:

Managed 64 hourly employees for this ~ $6M sales electronics job shop.

General Electric, Louisville, KY 3/1981 to 5/1984

Engineer:

Completed assignments in evaluation, structural analysis, heat transfer analysis and product engineering.

EDUCATION Bachelor of Science, Purdue University – Mechanical Engineering

CERTIFICATION PMP License

TRAINING GE: Edison Engineering Program accredited by University of Louisville, Product Functional Analysis (DFMA)

Boeing: Earned Value Management (EVM), Project Scheduling, Process Based Management, Self-Directed Work Teams, Integrated Product Teams (IPT), MRB (Material Review Board), DFMA (Design for Manufacturing and Assembly), Front Line Management

Airbus: GRAMS/GRESS training

APPLICATIONS MS Office, MS Project, MS Visio, ENOVIA, Western Data Systems (WDS) ERP, IQMS Esterline NMC ERP, eVSM (electronic Value Stream Mapping), ETC Manager, Structured Solutions (SSI) MS Project and Power Point Tools, Honeywell Milestone Reports (HMR)

AWARDS McDonnell Douglas Silver Eagle Award for C-17 Durability Test (1994)

LINKEDIN https://www.linkedin.com/pub/russ-chadwell-pmp/33/910/6a

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