Engineer

René Zandonella (Mr.)

**** ******** **** **** ***********, CA 95667 775-***-**** **************@*****.***

ASSETS

•Able to resolve complex issues into elements that can be communicated to people and organizations with varying levels of understanding for effective problem solving.

•Assignments and projects tackled with a focused, solution-driven approach carefully calculated to be cost effective and provide “value added” results.

•Managed successful proposal efforts totaling over $200 million and projects over $150 million.

•Demonstrated ability to accurately assess a situation, evaluate risk and exposure, and develop and implement action plans that mitigate risk and lead to optimum solutions.

• Expert at intervening in crisis situations to turnaround companies and projects in trouble. Consistently able to capture the essence of complex budget/schedule problems, secure the necessary resources, and execute effective corrective actions to restore profitability and meet demanding deadlines.

• Transformed disparate groups of vendors and subcontractors into single cohesive teams that took pride in “getting it right the first time.”

EXPERIENCE

Manager, Project Engineering and Test Laboratory

Ensign Bickford Aerospace and Defense

December 2012 – May 2014 Moorpark, CA

-Led and mentored staff of six engineers, developing safe and arms, separation nuts, arm and fire devices, pyro valves and other ordnance devices.

-Championed Lean Product Development methodologies to shorten lead times and improve reliability/robustness of product design.

-Conducted failure investigations and served as technical lead on configuration control board.

-Responsible for operations of in-house environmental and functional test laboratory including staffing, budgets and conformance to customer test requirements.

-Greatest challenge was integrating three distinct company cultures and systems resulting from recent acquisitions by Ensign Bickford.

Project Manager

Nevada Industry Excellence

May 2006 – December 2012 Reno, NV

-Served as Strategic Partner with various firms as an Engineering and Management Consultant, Program Manager/ and Instructor. Consulted on lean, six sigma, ISO, product innovation implementations, growth strategies, employee retention, cultural change and strategic planning.

-As part of the National Institute of Standards Manufacturing Extension Partnership (MEP) focused on increasing profits and growth of small and medium sized manufacturers.

-Custom tailored implementation programs to meet the unique needs of manufacturers, consulting directly or contracting specialized resources as appropriate. Special expertise at initiating cultural changes necessary to ensure continuous improvement efforts are successful.

-Managed federal and state grant funded manufacturer assistance programs.

-Instructor at Community College. Courses have included Pre-Calculus, Algebra, Statistics, Human Relations, Business Communication, and Engineering.

Project Manager

Zandonella Consulting

April 2002 – May 2006 based in Reno, NV

-Led product development team that developed low energy explosive initiator for automotive inflatable restraint system. Developed alternative manufacturing processes to improve reliability and robustness of design. Served as customer liaison and championed internal engineering and production efforts.

-Consulting Program Manager for development of a low energy (750 mA all-fire, 250 mA no-fire) initiator used in automotive inflatable restraint system.

-Responsible for expediting initiator development through process validation testing. Generated and implemented development and test plans. Performed testing and analyses to identify root cause of initiator performance anomalies.

-Developed alternative manufacturing approaches to improve reliability and robustness of product in accordance with Statistical Process Control parameters.

-Performed testing and analyses to select bridgewire material and size to effect optimum no-fire/all-fire performance.

-Served as customer liaison with TRW and Ford Motor Company and coordinated internal engineering and production efforts.

Plant Manager

Precision Rolled Products (Krupp VDM Co.)

June 1999 – April 2002 Reno, NV

-Responsible for budgeting, P & L, engineering, OSHA/environmental compliance and managing 140-employee facility producing forged titanium and superalloy bar stock with annual sales of $70 million and throughput of 5.1 million pounds.

-Instituted Lean Manufacturing, self-directed work teams, performance incentive programs, production efficiency metrics and quality improvements to increase production volume by over 128% and production efficiencies by 53% in less than two years. Reduced employee turnover by 40% and accident rate by over 50%.

-Key elements of the continuous improvement effort were a focus on cultural change, aligning individual goals with corporate strategy, and concentrated efforts in SMED/quick changeover, 5S and TPM/equipment maintenance in the production processes.

-Production improvements were accomplished with virtually no capital investment in aging plant facilities (key process equipment is over 90 years old and extremely labor intensive).

-Modified process furnaces to reduce natural gas consumption by 30%.

-Identified and proposed numerous material handling and semi-automated equipment upgrades and other plant modernization capital programs to reduce touch labor requirements by up to 60% and support corporate plans for facility modernization.

Special Projects Manager

Firth Rixson Viking

October 1995 – April 1999 Verdi, Nevada

-Led largest capital expansion program in the history of the corporation ($15.3 million) which included installation of a state of the art Heat Treatment Facility, computerized 400 ton radial/axial Ring Rolling Mill and 3,000 ton hydraulic Ring Expander. Facility produced seamless rolled titanium and superalloy rings.

-Evaluated and rejected original program concept which called for installing new equipment in an existing facility which would have reduced production output by over 25% for the year during construction.

-Developed and executed new plan that came in under proposed budget, increased manufacturing floor space 15%, doubled furnace capacity and allowed the program to be completed ahead of schedule, within budget and with no disruption to ongoing operations.

-Responsible for system design and installation of titanium/superalloy/steel Heat Treatment Facility including tip-up furnaces, quench tanks and automated material handling system.

-Designed facility, established performance specifications and managed installation of the Radial/Axial Ring Rolling Mill and Ring Expander.

-Key to project success was evaluating, selecting and leading an international contingent of subcontractors.

-Implemented Six Sigma process control conforming to General Electric supplier requirements.

-Responsible for developing ISO 9002 certification plan and successful implementation of that plan to obtain unqualified approval in less than six months.

Project Manager

Zandonella Consulting

February 1993 – October 1995

-Consulting Project Engineer for Tracor on $9 million contract for foreign military customer to design, develop, manufacture and install fully automated fire control systems for launching off-board expendables (chaff and infrared decoys). Program included development of launchers, decoys and proprietary dedicated computer hardware and software.

-Instituted engineering and programmatic corrective actions to contain costs and satisfy customer delivery requirements. These controls reduced projected cost overruns by 50% and averted a threatened program cancellation by the customer for late delivery.

-Developed concrete and achievable design/performance criteria and project milestones. Assigned clear lines of responsibility for each aspect of the program. These changes resulted in a 47% reduction in direct labor charges to the program. Focused engineering effort on satisfying customer requirements.

Engineering Manager

Defense Systems Corporation (Hi-Shear Industries)

March 1990 – February 1993 Reno, NV

-Engineering Manager for Defense Systems Corporation (manufacturer of expendable countermeasures - rocket and mortar-propelled chaff and infrared decoys).

-Developed program controls and systems that emphasized accountability, planning and team effort. Led organization from “start-up” company to effective ongoing operation.

-Created and implemented technological and management solutions internally and with the customer (US Navy), that led to successful completion of a $23 million program that had been over two years behind schedule and 55% over budget.

-Court qualified (Armed Service Board of Contract Appeals) as an expert witness in mechanical and ordnance design, manufacture, test, reliability, performance and safety. Instrumental in a successful $75 million contract default termination appeal against the US Government based on defects in Government supplied design and performance specifications, resulting in commercial impracticability/impossibility.

Engineering Manager

Tracor Aerospace

May 1987 – March 1990 San Ramon, CA

-Engineering Manager for Tracor Aerospace in a new business unit formed to develop and produce electronic safe and arm devices for tactical applications.

-Assembled a diverse group of physicists, engineers, technicians and production personnel into a cohesive team focused on the practical application of state-of the-art explosive technology. The application of Situational Leadership skills allowed the group to realize its maximum potential.

-Designed and developed explosive/pyrotechnic powder processing, handling and loading equipment/procedures.

-Responsible for design, development, qualification and transition into production of various aero-ordnance (explosive) systems including exploding foil initiators, pyrotechnic delays and ordnance destruct systems.

-Assessed customer requirements, prepared technical proposals and cost estimates, developed innovative and cost effective design solutions to meet program requirements.

-Received Tracor “Blue Max” award for technical excellence and contributions to the company

Project Engineer

Explosive Technology

March 1982 – May 1987 Fairfield, CA

-Project Engineer for Explosive Technology (a major manufacturer of linear explosive products and aero-ordnance explosive/pyrotechnic systems). Responsible for the design, development, qualification and transition into production of aero-ordnance systems and subsystems. Assessed customer requirements, prepared technical proposals and cost estimates, developed innovative and cost-effective design solutions to meet program requirements. Provided overall direction to program staff members, served as customer liaison and developed required internal resources and external suppliers. Generated component specifications, manufacturing and test procedures, reliability and hazard analyses and other program documentation.

-Designed and qualified capsule separation system for the Sea Lance Missile and canopy severance system for the TAV-8B. The innovative design of the TAV-8B canopy severance system which increased reliability, lowered manufacturing costs and simplified installation on McDonnell Douglas’ production line, led directly to an $8 million contract award (taken from the incumbent contractor) for a similar system on the AV-8B aircraft.

Research Scientist

Solar Turbines (Caterpillar)

July 1979 – March 1982 San Diego, CA

-Developed patented process for net forming Titanium and superalloys while Research Scientist at Solar Turbines, Inc.

-Process utilized press with contoured Molybdenum rollers contacting the metal to be formed. Electrical current passed through rollers and metal to resistance heat and maintain forming temperature.

-Produced titanium foil of 0.005 inch thickness in one pass from one inch thick bar stock. Turbine engine ring forming from nickel base superalloys. Formed net shape Titanium "T" longerons for F-18 aircraft from solid bar stock in two passes through mill. Designed and implemented preheat scheme and atmosphere controlled section to prevent oxidation and intergranular corrosion of metals being formed.

-Installed scaled up pilot production mill at customer’s (International Nickel Corporation) facility. Prepared proposals and production cost analyses.

-Accomplishments included forged engine ring preforms and turbine blades for General Electric and Solar Gas Turbines.

-Designed and fabricated solar energy radiation receiver for Stirling engine based renewable energy system.

-Authored and presented technical paper on isothermal forming process at 26th National SAMPE symposium.

EDUCATION

Master of Business Administration, Management 1988

Golden Gate University, San Francisco, California

Graduated with Honors, 4.0 grade point average

Bachelor of Science, Engineering 1979

Harvey Mudd College, Claremont, California

Graduated with Honors and Distinction, National Merit Scholar,

California State Scholar

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