THEO G. KOUMARIANOS
Indian Harbor Beach, FL 32937
To obtain a Manufacturing Engineer, Supplier/Quality Engineer, Product Engineer or Management position utilizing my experience and education.
A Highly experienced manufacturing specialist in the Aviation/Aerospace Defense Industry. Hands on experience with Military/ Civilian Aircraft, Space Shuttle, Space Station, Delta ll, lll, & lV Rocket program. Titles held: Manufacturing engineer, Quality Engineer, Hardware Engineer, Safety Engineer, Reliability Engineer, Planner, QA Inspector, Electrical & Mechanical Technician on various aircraft and rockets. Experience with 5S lean and Value Stream Leadership. Perform RCCA, PFMEA & DFMEA. Hold MRB authority. Performed major modifications, overhauls, & maintenance on Aircraft & Rockets. Integrated Hardware, Software Integration, Software testing & Validation. Write repair procedures, Planning, Scheduling, Analyzing as well as Technical writing. Over 12 years’ experience with exotic composites. Develop policies and procedures.
FAA Certified Airframe and Powerplant License
FAA Certified Commercial Pilot, Instrument Rating, Single and Multi-engine
Certified on Various Aircraft.
Certified on Garmin & Avidyne FMS/GPS/NAV/COM Systems
Held Top Secret Clearance with DOD
Lean Manufacturing Certification
NASA Certified Quality/Reliability Inspector
VCMM & CMM Operator
DOT Commercial Driver License; FL CDL CLASS A with TPX Endorsements
UTAH VALLEY UNIVERSITY
BS Aeronautical Science & Aviation Professional Pilot
FLORIDA INSTITUTE OF TECHNOLOGY
Flight Technology/Commercial Pilot
COLLEGE OF AERONAUTICS
Aeronautical Engineering and Maintenance Technology
AWARDS AND ACHIEVEMENTS
7 Commendations from NASA and Lockheed Space Operations company
5 Kennedy Space Center certificate of appreciation for outstanding performance
33 Kennedy Space Center, Boeing Accomplishment/Appreciation Awards
Aircraft worked on/supported: Boeing 747, 767, 737, and 727, L-1011, DC-9, MD80, A300, C-130, C5B, P3, F-22, F-35, F5, E2D, A6, B2B, T-38, F-18, and Embraer Super Tucano & NASA Classified Experimental Aircraft.
Helicopters worked on/supported: Sikorsky S-60/61, S-92 Bell 206L, 222, 407, UH1 Huey, Augusta A109 variants and Aerospatiale Dolphin and Gazelle.
SPACECRAFT worked on/supported: SPACE SHUTTLES OV-102, OV-103, OV-104 & OV-105. DELTA ROCKET ll, lll and lV including Classified Satellite’s.
PIPER AIRCRAFT, Inc. – Vero Beach, FL.
01/2017 – current
Sr. Quality Engineer
Implement strategic plans initiated by the Quality Department.
Analyze nonconformance data to establish trends on recurrent nonconformity utilizing statistical tools.
Perform internal audits in accordance with Quality Assurance manual.
Interface with Engineering, customers, and suppliers on quality issues.
Investigate root cause and corrective action for discrepancies targeted.
Participate on the Corrective & Preventative Action Review Board.
Make recommendations to eliminate measurement system error.
Evaluate Piper Process Specifications (PPS), engineering drawings, and other acceptance criteria to verify quality characteristics or functions.
Analyze production and service limitations and standards; recommend the revision of specifications, policies, and procedures.
Application of statistical quality control and statistical methods for the purpose of measuring and improving the quality of processes.
Performed supplier audits, approval, disqualifications and other functions to maintain acceptable levels of supplier quality through continuous improvement.
Design, install, and evaluate process sampling systems and statistical techniques.
Recommend strategy for warranty claim issues.
Non Destructive Testing (NDT)/ Inspection
Review Quality manual to ensure recommended revision in procedure is instituted.
CRAIG TECHNOLOGIES – Cape Canaveral, FL. (TEMP)
05/2016 – 12/2016
Quality Engineer (Avionics) Manufacturing
Performed same work as Northrop Grumman to include Avionics and Electrical components, NAV & Guidance systems, Fiber-optics, PCB, electrical wire-harnesses, soldering, testing and repair. Software testing, validating and integration.
Conduct and documents detailed failure analysis of electronic and electro-mechanical assemblies.
Guiding Planners and writing Routers/Work instructions from customers P.O.’s
Creating New Processes for new incoming work. Improving existing processes to improve time and product, Evaluate technical dispositions impact on production schedules, safety, quality aspects, documentation and costs.
Documents failure investigations of avionics.
Facilitate dispositions for non-conformities detected on supplier components responsibility. Monitor manufacturing yields during contract manufacturer’s production operations.
Initiate product design changes as required. Support the integration of reliability data and statistics into a common database. (MES-NC)
Validated supplier’s dispositions for non-conformities in case such supplier is not delegated as MRB
Retrieve data analysis; look for trends and high drivers. Initiate RCCA.
Supports product testing, training, troubleshooting, and repairs at contract manufacturer and repair shop.
Support system level troubleshooting during product deployment and in-service operations.
Assists in the development and preparation of a monthly system reliability reports and presentations.
Develop new, and modify existing, LRU test equipment, methods and procedures.
AAR AEROSTRUCTURES and AEROSPACE - Clearwater, FL. (CONTRACT) 09/2015 – 12/2015
Sr. Manufacturing Composites Engineer
Participate in development of new and unique manufacturing processes with teams consisting of manufacturing, engineering, and supplier personnel.
Lead analysis and design of composite manufacturing processes and materials in optimizing designs, improving performance, reducing weight, and cost.
Evaluate and test alternative materials as they relate to improving process capability and product integrity.
Coordinate and conduct product testing required to guide development and validate that the product meets all specifications.
Project management is conducted through the use of project schedules and plans developed to meet overall project goals and timelines.
Develop specifications and statement of requirements for materials and processes that meets long-term production demands for the lowest investment possible.
Developed statement of work (SOW) for parts and requirements. Certified on FIBERSIM program laying up materials. Work and support Spray Lay-up, Film Adhesive’s, Carbon Fiber, Kevlar, Graphite, Vacuum Bag Molding, Autoclave’s and Ovens, Thermo-couples, Molds and Hand Lay-up and Co - cure.
Follow-up and lead implementation of new materials into production.
Lead FEA, FMEA and DFM analysis as required, to understand and optimize designs.
PALL AEROSPACE New Port Richey, FL. (CONTRACT) 06/2015 – 09/2015
Sr. Manufacturing Engineer
Directly support the fabrication of Military and Commercial Components for: Aircraft, Helicopters, Rockets, Missiles, Submarines, Ships, Specialty Vehicles and crafts and tooling
Planning & Created Routers from customer P.O.’s
Ensure that all parts are received & inspected at the correct time to facilitate the build schedule
Create and maintain shortage lists as required
Participate in component and tool design and development
Developing production procedures/processes.
Develop & Create new Work Instruction (W.I.) for component build-up/fabrication
Resolve manufacturing discrepancies and interface with the cross functional teams
Develop and maintain standard routings, repair routings and special instructions.
Develop and maintain standard inspection plans
Disposition nonconformance products for repair, test product and return product to blueprint configuration/ tolerances and return component to service
Created and approved routers/work instructions for new incoming work from P.O.’s.
Work and direct machinist in machine shop for fabrication and design of product
REGENT AEROSPACE/AIRBASE SERVICES, Jacksonville, FL. (Plant Shut-down)
Manufacturing Engineer 08/2014 – 02/2015
Same work performed as PALL AEROSPACE
NORTHROP-GRUMMAN AEROSPACE St. Augustine, FL. 08/2011 - 07/2014
Sr. Quality/Supplier Engineer
Develop, modify, apply and maintain quality evaluation and control systems and protocols for processing materials into partially finished or finished materials product.
Collaborate with engineering and manufacturing functions to ensure quality standards are in place. Devise and implement methods, processes and procedures for inspecting, testing and evaluating the precision and accuracy of products and production equipment.
Design and analyze inspection and testing processes, mechanisms and equipment; conduct quality assurance tests; and perform analysis to assess the cost of and determine the responsibility for, products or materials that do not meet required standards and specifications.
Audit quality systems and manufacturing processes for deficiency identification, correction and improvement. Ensure that corrective action measures meet acceptable standards and documentation is compliant with requirements.
May specialize in the areas of design, incoming material, production process control, product evaluation and reliability, inventory control and/or research and development as they apply to product or process quality.
Conduct Root Cause Analysis, PFMEA, and DFMEA. Write Corrective Actions to non-conformance issues; work with Supplier on Supplier Corrective Action Requests (SCARS).
Leading Failure Review Board (FRB), Material Review Board (MRB) Authority, and Corrective Action Board (CAB) for their assigned products/programs and the organization. Member of Material Review Board (MRB) team.
Supplier Quality. Working with Product design, fixtures & equipment.
Supporting Operations, Engineering, Program Management and other functional groups by providing trend analysis and root cause analysis investigations, as well as corrective action recommendations.
Leading FRACAS effort for Quality Assurance as required and providing corrective action, trend analysis, and failure documentation.
Work and Audit to AS9100C, AS9102, ISO9001 and IEC606-1 I Contact vendors in determining product specifications and arranging equipment, parts, or material purchase, and evaluating products according to quality standards and specifications.
Worked with Auto CAD/CAM, Visual Pro V and Solidworks.
LOCKHEED MARTIN Aeronautics Company, Dobbins AFB, Marietta GA.
Manufacturing Process Engineer 05/2009 – 08/2011
Performed same duties as PALL AEROSPACE and AAR Aero-structures
BOEING Integrated Defense Systems, Kennedy Space Center, FL 09/1997 – 05/2009
Quality Assurance/Quality Engineer
Worked on the Delta Rocket Program and transferred to International Space Station
Worked with Mate De-Mate of Electrical Cables & Umbilical Cords to Space Launch Vehicles, Delta Rocket, Space Shuttle and Space Station.
Worked with Hydrazine, Ammonia, Cryogenics, and Various Rocket Propellants.
Verify/witness the fabrication, assembly, installation, repair, test, checkout, fault-isolation, calibration, operation and performance verification of mechanical, structural, electrical components, build-up of electrical wiring harnesses, connectors mate/demate, bonding and bonding jumpers, electronic, hydraulic and pneumatic systems, ground-handling support equipment, ground and /or flight computers, and telemetry, optical and/or electro-mechanical equipment, test equipment, and assemblies for launch and spacecraft systems and subsystems at launch and test sites.
Perform hands-on inspection of flight and GSE/GFE hardware as assigned.
Verified assembly, disassembly, and fabrication and testing of critical space Shuttle & Rocket payload flight equipment to meet precise requirements. Process quality records per appropriate procedures to maintain accountability, acceptance and status.
Fabricated/worked with; Fiber-optics, PCB, electrical wire-harnesses, soldering, electrical components, testing and repair. Software testing, validating and integration.
Developed and executed procedures for checkout and integration of launch flight hardware, spacecraft and ground support equipment.
Lead launch vehicle and payload processing activities.
Helped developed, build and maintain vehicle and spacecraft payload processing facilities.
Closely collaborate with engineering staff from other departments, customer, technicians and inspectors on a daily basis.
Trouble shot and came up with solutions to technical problems with team members and customer.
LOCKHEED SPACE OPERATIONS COMPANY - Kennedy Space Center, FL. 03/88 - 08/99
Space Shuttle Technician/Inspector
Uploaded/downloaded installation Satellites, Payloads of mission kits, space laboratory, Secret satellites, and Secret experiments into shuttle payload cargo bay areas.
Performed checkout, testing, verification, modification, repair, overhaul, installation, trouble-shooting, adjustment, and calibration of complex shuttle electrical/mechanical systems and components.
Fabrication of electrical wiring harnesses, connectors mate/demate, bonding and bonding jumpers, soldering. Participated in shuttle launch operations.
Worked with exotic composites.
Performed major modifications on airframe structures to include cockpit and rework of assigned systems and components.
Participated in all phases of shuttle integration, as well as control systems and launch operations.
Located, diagnosed, and rectified malfunctions and documented recommended corrective action.
Installed/replaced major components shuttle systems.
Worked with cryogenic, hypergolic and solid propellants.
References and additional information upon request.