Manager Manufacturing

Robert Gulley

**** **** **., *******, ** ***** § 252-***-**** § ***********@*****.***

Manufacturing / Engineering Director

Over 15 years of leadership experience that includes Senior Manager position with Boeing/Vought/ Spirit. Extensive background in the aerospace industry, including a continual record of success in project management, team building, process optimization, and quality assurance within manufacturing environments. B.A. degree and Master’s Certificate in Project Management.

Overview: Quality-driven, process-oriented leader with strong strategic and tactical background in manufacturing and production environments, directing large teams and complex facilities. Positive, collaborative, and motivational leader who builds successful relationships with team members, vendors, and partners, including global collaborations. Extensive knowledge of engineering design principles, manufacturing/production systems, and tooling functions.

Core skill areas: Continuous Process Improvement § Lean Manufacturing § Composites Manufacturing § Kaizen & Kanban Methodologies § Cross-Functional Team Leadership § Safety & Quality Programs § Change Management § Total Quality Management § Program Development & Launch § Project Scoping & Scheduling § Global Teamwork

Professional Experience

SPIRIT AEROSYSTEMS – Kinston, NC – 2012-Present

Deputy Program Manager

Manage all day-to-day activities within the Program Office, supervising 2-3 first-line managers and 30 indirect reports. Oversee support for leading-edge spar and flaps for gulfstream program. Additionally direct team of 20 in maintaining configuration of programs and administering Program Change Control Board. Serve as backup Change Board Chairman in absence of Director of Programs.

Led major Lean initiative to develop and implement new strategy for working on Airbus assembly sites, resulting in $7 million-plus cost avoidance. Contributed to additional Lean initiative that resulted in ~4-month schedule recovery, as well as processes for working on change control, change board, and change implementation.

Directed team in 1st development of program delivery schedule and worked out process with internal scheduling team on flowdown and schedule control activities.

Reduced delinquent events from 1,200+ to 16 in 4 months. Worked with IPTs and functional groups to close out remaining actions that impacted Type certification, First Part Qualification, Testing, and others.

Served as the on-site program leader and customer liaison in Toulouse, France, addressing and resolving program/operational issues. Recognized by customer team for efforts.

Implemented IPT structure across both S15 and spar in a joint effort with customer in Kinston.

BOEING COMMERCIAL / VOUGHT AEROSTRUCTURES – Charleston, SC – 2007-2012

Senior Manager, Manufacturing Engineering (2009-2012)

Served as the Senior Manager over multiple areas, including: Composite Fab M.E.; Assembly M.E.; Structural Integration M.E.; MRSA; Manufacturing Model Group; and NC Programmers (all for both Aft and Mid-Body). Led team of 4 first-line managers and 120 direct reports.

Achieved final cost avoidance of over $6 million following transition of M.E. Statement of Work from Vought to Boeing, SC, completing project in 18 months.

Created process that reclaimed $1 million-plus in obsolete inventory; served as the technical SME regarding build/process issues for the Aft Leader.

Managed every major NOE originating in Charleston, with majority requiring extensive cross-functional and executive leadership updates/actions.

Implemented 3 major blockpoint changes with the team as well as a new format of work instruction that provided mechanics on the floor with a clearer direction.

Senior Manager, Manufacturing Engineering (2008-2009)

Contract Manufacturing Engineer to Vought/Lockheed Martin (via PDS Technical) (2007-2008)

Hired for contract position with Vought/Lockheed and earned subsequent advancement. As Senior Manager, oversaw all Production Operations functions, supervising 4 production managers and over 300 mechanics.

Spearheaded resolution of scheduling, technical, and operational issues through effective interactions and collaborations with subordinate supervisors.

Ensured compliance with company policies and regulatory requirements through individual and team leadership efforts; served as a mentor to both first-line managers and direct reports.

ADAM AIRCRAFT – Pueblo, CO – 2006-2007

Plant Manager

Managed all aspects of the company’s Pueblo facility, including the fabrication and assembly of the Adam A500 and A700 Composite Empennage (tail assembly). Led team of 58 direct and 29 indirect reports. Functioned as the on-site leader for initiatives such as the company-wide Production Improvement Project. Managed $2 million in raw materials, including forecasting and ordering activities.

Achieved 40% direct hours reduction for layup of major parts through implementation of multiple process improvements. Additionally achieved 40% cost reduction on layup of empennage skins.

Developed comprehensive Preventive Maintenance Plan for production tools, implemented 5S program for the facility to improve quality performance, and created Master Production schedule from fabrication to delivery.

Led the facility’s transition from a developmental to a full-rate production operation.

HAMPSON AEROSPACE – Grand Prairie, TX – 2005-2006

Engineering Manager

Led team in set up of assembly and build process for Eclipse 500 Empennage in Grand Prairie, with matrix responsibility for 4 engineers in the U.K. that supported machining, fluid form, and sheet metal part fabrication. Served as a Technical Advisor for the management team on issues relating to Assembly Tooling, Assembly Flow, Factory Layout, and others. Developed budget for all tooling and consumables to support build rate.

Led build-out of first 5 production ship sets and prove-out of assembly tooling, supervising and coaching Assembly team of mechanics and engineers in Glossop, England.

PRIOR POSITIONS:

Manufacturing Engineering Supervisor/Flight Test Program Manager, Eclipse Aviation – Led team in development, maintenance, release, and scheduling of all planning for build of 7 flight test airplanes. Directed team of aircraft manufacturing technicians in installation of all flight test parts. Integrated entire test flight build package within manufacturing build sequence. Served as the SAP subject matter expert for Manufacturing Engineering.

Multiple Supervisory & Non-Supervisory Positions, Boeing Commercial Airplane Company – Built distinguished record of achievement and advancement through increasingly responsible positions. Key contributions and accomplishments included: assisted in implementation of new 747 derivative airplanes; ensured on-time delivery of high-quality products and fulfillment of financial goals; and resolved all issues to facilitate build of first 767-400.

Education & Credentials

B.A., Business Administration: WESTERN WASHINGTON UNIVERSITY, Bellingham, WA

Master’s Certificate in Project Management: VILLANOVA UNIVERSITY, Villanova, PA

Professional Training: Lean Training: Kaizen events, Value Stream Mapping; Leadership Training: First Line Management, Senior Management Leadership Program- Pacific Institute

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