Gregory C. Hildebrand

*** ********* **.

Middletown, CT 06457

712-***-**** (H)

860-***-**** (C)

acadjy@r.postjobfree.com

http://www.linkedin.com/pub/greg-hildebrand/5/524/723

Summary

Creative project management engineer with a Lean/Six Sigma Black Belt and experience in

research and development and product development. Proven track record in all phases of project

management and technology development – conceptualization and planning, conceptual through

detailed design, prototyping, testing, TRL progression, and transition to production. Led a $75M

proposal development effort. Was among the first at Pratt & Whitney to use A3 management.

Technical & Specialized Skills

Lean: A3 Management, PDCA, DMAIC, ACE, Value Stream Mapping, Root Cause, CDOV,

Corrective Action, 5 Whys, Process Mapping, SIPOC, Standard Work, QFD, HOQ,

Benchmarking, Kaizen, Setup Reduction, QCPC, Cell Design, Continuous Flow,

Visual Control, Mistake Proofing, KJ Analysis, I2DOV

Six Sigma: Design of Experiments (DOE), FMEA, Gage R&R, Regression Analysis, Power and

Sample Size Analysis, Process Certification, Control Charts, ANOVA, Confidence

Intervals, Student T Test, Paired T Test, Correlation, Risk Analysis, DFSS, Multi-Vari

Analysis, Red X, SPC, Reliability, BOB and WOW

TOC: Constraints, Current Reality Tree, Evaporating Cloud, Throughput, Inventory and

Operating Expense

Others: Project Management, MS Project, MS Office, Minitab, Composites (OMC and CMC),

NDE, Castings, Injection Molding, Work Instructions, TRL Development, SAP

Professional Experience

Quatro Composites, Orange City, Iowa 2013

Manufacturer of composite aerospace and medical parts, $35M, 150 employees

Director of Quality and Systems Improvement

Directed the development and implementation of company-wide Lean systems. Directed the

resolution of customer, vendor, and internal quality issues. Managed activity of QA Team Leads

and Quality personnel on both shifts to maximize productivity of the QA department. Oversaw

document control processes, and the development and deployment of work instructions.

• Developed a course in A3 Management and deployed it in multiple departments.

• Initiated a “Delivery and Quality Clinic” to improve company performance metrics.

• Directed cross training to eliminate QA specialties that were one or two deep.

• Worked with the Director of Compliance to add rigor to the development of Work

Instructions.

Pratt & Whitney, Middletown, Connecticut 2000 - 2013

Manufacturer of aircraft engines, $13B, 36,000 employees

Hardware Production Manager

Worked with designated suppliers (TurboCombustor Technologies, Whitcraft, PCC, etc.) to

improve their delivery and quality performance. Addressed both immediate and long-term issues.

Worked on a team assigned to advance the Lean maturity level of a procurement organization.

• Made key contributions in Value Stream Mapping and creating a SIPOC that enabled the

procurement organization to advance two levels of Lean maturity in 6 months.

• Helped a foreign supplier to resolve welding issues that had been causing an andon

situation.

• Used QCPC to manage the transition of a family of 32 parts from one sub-tier supplier to

another, while under constantly changing demand rate. This reduced turnbacks by 98%

over a 5-month period.

• Devised a statistical test to quantitatively compare two inspection methods, proving they

were equivalent, and avoiding a 71% cost increase and probable partial fleet inspection.

• Initiated an A3 Management project to improve one supplier's on-time deliveries from

below 50% to over 90%.

Senior Staff Engineer

Rewrote major composites processing specs, incorporating improvements from several sources.

Served as the P&W focal point for a series of Air Force ManTech (Manufacturing Technology)

programs, coordinating the research and product development efforts of multiple vendors, OEMs,

the government, and various departments within Pratt. Aided in the design of experiments, applied

statistical tools to test data, assisted in the development of test matrices, and analyzed the

reliability of systems. Worked with multiple small companies to give guidance to their SBIR

programs. Assisted with the fan blade development of a next generation commercial aircraft

engine.

• Successfully built business support for the use of QFD on a major new design initiative.

• Completed a revision of 4 major composites processing specs within in 3 months, meeting

a very difficult deadline.

• Designed an extensive database of manufacturing and processing data for ceramic matrix

composite parts to document all important processing parameters

• Identified a system that had a 22% chance of failure based on a reliability analysis of test

data. A material change and redesign of the parts resolved the issue.

• Patent pending for a fan blade tip treatment invention.

Integrated Product Team Leader

Conceptualized, planned, and implemented an R&D Icephobics program, which included a

combination of theoretical and empirical research, testing, and finite element analysis. Led the

development of a ManTech proposal worth $75M for improving the throughput and reducing costs

associated with composite engine components. The composites proposal was one of six parts of

a ManTech Phase 0 program. Developed quotes for key portions of new contracts, including

coupon and subcomponent testing, risk management, and all stages of design. Worked closely

with the Technology Manager to establish technology development plans and prioritize potential

future technologies based on payoff, feasibility, and cost. Participated in product line strategy

discussions.

• Was praised by the ManTech Phase 0 Proposal Managers saying my proposal “made the

other sections look bad in comparison.”

• Developed and implemented an R&D program to predict when ice releases from an airfoil.

Experts from the Army’s Cold Regions Research and Engineering Laboratory called it, “the

best plan we’ve ever seen.”

• Honored with a Pratt & Whitney Eagle Award for the Icephobics program, which was 5

times more successful than expected, and completed on time and on budget.

USAF Advanced Composites Program Office, Sacramento, CA 1989 to 2000

Part of the AFRL, the scientific research arm of the US Air Force, $2.4B, 5,400 employees

Aerospace Project Engineer

Assigned to investigate and report on maturity of a new “smart skins” technology upon joining the

USAF ACPO. Managed an ultrasonic cutting facility for the Air Force. As a project engineer,

responsible for the entire life cycle of projects including failure analysis, problem solving,

preliminary and advanced design using several CAD packages, finite element analysis, tool

design, prototyping, testing, and manufacturing support. Co-taught an Air Force-internal college

level course on composites theory.

• Briefed top management (up to 2-star Generals) on “smart skins” within six months of

assignment.

• Filed for 2 patents on smart skins within 1 year of assignment (only one was eventually

awarded).

• Achieved up to 71% material savings and 98% labor savings on individual ultrasonic cutter

projects.

• Sought out by an industry leader as the DoD representative in an international effort to

develop next-generation composites manufacturing and repair equipment.

• Revamped the matrix algebra section of the composites theory course.

Previous experience includes NADEP North Island (US Navy) and Bell Fiberglass Co., Houston

MN.

Education

Master of Science in Engineering Science

Rensselaer At Hartford (graduate school extension of RPI), Hartford, CT

Lean/Six Sigma Black Belt certification

Master of Science in Aerospace Engineering and Engineering Mechanics

San Diego State University, San Diego, CA

Bachelor of Science in Physics

St. John’s University, Collegeville, MN

Professional Development And Memberships

• Lean/Six Sigma Black Belt Certification

• American Society of Quality, former Voice of the Customer Chair, Hartford Section

• Sun Certified Java Programmer

• Entrepreneurial Training

• Security clearance (inactive), US government

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