Engineer Engineering

Sam Bose

********@*****.***

Professional Summary

Successful 23 years of aerospace industry experience in process

(562)212-0528development & implementation of cost control measures to ensure Manufacturing operations remain within company targets. Expertise background in Cast metals industry.

Core Qualifications

Manufacturing Process Engineering Support for Design and Manufacturing Engineering for F-35 Composite parts, Process Improvements & Manufacturing Technology Development of new Processes, Equipment, Cost Improvement

& Affordability in F-18 program.

Recognized technology expert that demonstrates advanced knowledge in Composites process engineering and assembly integration.

Major Accomplishments / Career Experience

Northrop Grumman Corporation, Integrated Systems Sector, El Segundo, Ca Manufacturing Process Engineer, Engineer 5, F-35 Program June, 2004 – July 2014

Provided comprehensive producibility & affordability guidance to Engineering Design Teams in F35 Program. Supported Standard Tool budget control and material allocations for F-35 & F-18 parts within established targets.

Supported Seamless Transition of Integrated Supplier and Mitigate Transition Shortages through alternate methods.

Reviewed BTPs for producibility activities in support of Skins, Doors, Mechanisms & Subsystem team BTP release. Work processes included evaluation of CATIA Models for checking drilling, countersinking & fastener installation on fixed structures, as well as fabrication requirements.

Responsible for equipment selection, optimizing of cost effective cutter & Standard Tool requirement and procurement for Composites Manufacturing, Advanced Paint & Coating Centre and Paint & Seal area.

Used technology expertise to solve challenges and guide decision-making processes such as the authoring of Process Work Instruction documents and Qualification reports.

Dynamic role for approval and rating of BTPs in established dept. EV data base. Reviewed Visual Aids, ALOOs for assembly sequences. Interfaced with Designers, MEs & IPT teams.

Development work of Algorithm for updating existing software for Steps and Gap measurement on highly contoured Composite surfaces using Laser gage.

Development of Installation of In-Flight Refueling Doors, Weapon Bay doors, Lift Fan Bellmouth, Gun Trough Mechanism and Skin, Bootstrap and Skin, Load Fittings, Heat Exchanger Lips, Gun Port Door assy., Sub-assembly.

Developed tool design for improved producibility of Gun Vent Drilling. Supported development of One Shot Drilling process for manual drilling in Inlet Ducts & Burr less Drilling project. Responsible for Grommet Installation tool development for constrained areas & its implementation.

Developed ergonomically designed Tooling for Installation of Captive fastener in constrained areas. Designed & developed Inspection tool for post installed grommets. Designed, fabricated & implemented various go no-go gages.

Generated Qualification test report for LMA’s approval of right angle tool for Captive fastener installation. Generated & Updated PWIs (Process Work Instruction) & PCNs that address Engineering requirements per Process Specs for Composite fabrication & Autoclave curing, Sub-assembly & Hand Trim & Drill cell.

Cost savings by retrofitting non-compliant countersink gages to efficient, compliant & standardized Countersink gages.

Proposed & investigated feasibilities of FTI GromEx Technology for grommet installation thereby attaining Weight savings & Touch labor reduction.

Implemented programmable & lockable Heat guns in Composites Manufacturing Clean room.

Worked closely with Quality Engineering, Audit, M&P, Manufacturing Engineering, Design Team, Component & Standard Parts Engineering, Manufacturing, Environment & Health & Safety department. Reference to AMS, ASTM, Mil-STD, NAS, SAE specifications as reqd. Northrop Grumman Corporation, Integrated Systems Sector, El Segundo, Ca Manufacturing Technology, Engineer 5, F-18 Program, July 1991-June 2004

Performed Manufacturing Technology development projects inclusive of laboratory studies & Production implementation.

Responsible for equipment development with strategy control. Led and supported Tactical Aircraft Assembly and Composites Process/Methods improvement.

Provided technical study & support for improvement of Airframe manufacturing affordability, bonded assembly, fabrication & machining throughput, reduced process variability and assembly producibility. Implemented state-of-the-art tooling materials & manufacturing methods.

Supported Management in project planning, execution, and budgetary control of ongoing projects, implementation of lean practices, execute goals & manage resources. Interfaced with other departments and developed effective empowered teamwork.

Teaming communication activities with Suppliers and NCDMM & NCEMT research Establishment. Phase One of J-UCAS Metal Working Technology R&D program related to J-UCAS Airframe structure for weight reduction & cost savings.

Supported NCTA projects for initiation, development and production validation. Developed and implemented Single Step Drilling on H-skin, NC Trimming Step reduction from four to two of large size Composite parts, and Pin Waterjet & Abrasive Waterjet Trimming of small, complex Composite parts, NC machining of metallic Honeycomb cores.

Demonstrated drilling full size hole on Aermet 100 spindle material in single step using Orbital Drilling. Developed PCD countersink cutter with integral fillet radii, & Implemented.

Developed and implemented ergonomically designed Oscillating saw for cutting prepreg material for Hats for z-pinning. Eliminated high pitch noise level for z-pinning process.

Managed selection, procurement & production implementation of Z-pinning equipment.

Developed & Implemented LVDT Measurement System for Verifilm Thickness Measurement.

Generated multiple Qualification reports for process specifications approval from Boeing and multiple Northrop Grumman common process specifications.

Eliminated Flaring crack problems in Aluminum tubing fabrication. Minimized porosity of Ti-70 & Ti-40 hot bending tubes. Implemented ultrasonically cleaned fittings for Orbital Welding of Ti tubes & lean cleaning process of tubes. Worked on various ETA projects. Converted MIL-H-5606 Hydraulic Fluid to D.I. water for pressure testing of tubes. Implemented Non-Oil based Cutting Fluid, Water Soluble Lubricants for Tube Bending. Formulated Specifications for Tube and Core cleaning Equipment Systems. Stoody Deloro Stellite, a Division of Thermadyne Corp. City of Industry, Ca, 1988-1991 Senior Metallurgical Engineer

Process control and development in manufacturing of Stellite, Haynes and Deloro alloys of cobalt, nickel and iron base hard facing alloys, continuously cast welding rods, fabrication of tube wires

& wear resistant centrifugal castings for military and commercial applications.

Responsible for the development of large size balls for oil well industry, bimetallic liners with flights, Monel-H alloy castings.

Developed new products in centrifugal castings, cast and fabricated tube wires. Improved melting practices and quality of cast rods. Heat treatment, melting, metallography and failure analysis, weld test, computer applications. Formulated manufacturing procedures.

Responsible for process improvement, reduction of value added inventory of materials. Hazardous waste minimization and VOC control.

Allied Signal Inc., Airesearch Casting Co., Torrance, Ca, 1984-1987 Process Engineer

Process development and control of A-201, A-356 & A-357 aluminum alloy castings for aerospace application. Developed making thin-walled A-201 and A-357 alloy castings. Proposed plans for squeeze castings for impellers and wheels, cast composite fabrication techniques of aluminum alloy cast products

Comprehensive control of process engineering in various grades of stainless steel, ductile Ni-resist and iron castings in shell and airset molding practices.

Gating, risering, heat treatment, welding, brazing, non-destructive testing. Improved melting practices. Development work in proprietary alloy products and attached mold process. Formulated process control procedures.

Texas Steel Company, Fort Worth, TX; St Stephen, Canada 1981-1983 Quality Control Engineer, Quality Control Manager

Responsible for transferring V-process (vacuum mold) technology from pilot to production for steel castings. Comprehensive quality control inspection, radiography, dimensional layout & target fixtures.

Gating & risering, metallurgical control in V-process and no-bake molded steel castings. Quality control procedures, quality assurance with customers. Education

PhD-Loughborough University of Technology, UK

MS-Mechanical Engineering, IIT, Kharagpur

BS-Metallurgical Engineering, IIT, Kharagpur

Security Clearance-Secret

Skills CATIA V5, MES, GD&T, Composite Applications, NDE inspection methods, AS-9100, ISO 9001-2000, Fishbone, PFEMA. PMP. Producibility analysis for skins, Doors and assemblies using Catia Model. Machining/Drilling processes. Expert knowledge, selection of optimized tool for drilling, countersinking, fastener installation processes in Composites and Composites/Metal stackups. Develop Process Work Instruction, Common Process Specification, Materials and Processes. SPC, DOE techniques. SEM /EDS, EPMA, Metallography, Failure analysis, Casting (Steel, Ductile & Gray iron, Super alloys, Aluminum alloys), Melting, Welding, Heat Treatment, Forming processes. Work well across multi-functional environment requiring strong technical skills and proactive leadership to support the production execution to meet on time schedule. Self-starter, problem solver who works well in a design/ production team environment.

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