Engineer Quality

JAMES MICHAEL OSBORNE

480-***-**** (mobile)

email : ****.*********@*****.***

SUMMARY

Degreed Engineer with full life-cycle experience including development, test, certification and production of aircraft, electronics, and renewable energy systems, customer in-service support, supplier development, and manufacturing quality. Proven leader of teams on complex engineering, manufacturing transition, functional transformation, and continuous improvement programs. Collaborates and coordinates with internal work groups and external customers and suppliers to achieve optimal results.

COMPETENCIES

Six Sigma Green Belt

IPC (600-series and J-STD)

Lean

ISO 9001/AS9100

Value Stream Mapping

Nadcap

FMEA

SAP

SPC

Kanban

EXPERIENCE

ABB (Power-One) – Phoenix, AZ Sept 2014-Present

Manufacturing Quality Engineer

Co-led startup of assembly line retrofitting solar inverter modules to new standards. Led startup of a low-rate production line. Develop and oversee quality plans for new products for power conversion, including light rail traction systems. Chair regular issue resolution conferences with suppliers. Conduct First Build Audits and First Article Inspections. Focal point for customer Quality audits. Monitor manufacturing quality data for trends, resolve conformity issues, and interface with supplier, customer, field service, and audit personnel. Solicit and implement Quality improvement ideas from assembly personnel.

HONEYWELL INTERNATIONAL – Glendale, AZ Oct 2013-Apr 2014

Quality Engineer (Contract Position)

Led data-based investigations into production process quality and producibility defects to identify and resolve problems. Used SAP to track defects. Presented Quality results and reviewed processes for continuous improvement.

Developed and analyzed statistical data and product/process performance to recommend and implement continuous improvement in targeted areas using FMEA, 8D root cause analysis, 5-Why's, SPC, and control plans

Provided support in the way of development and evaluation of process capability, process control plans, and analysis of out-of-control conditions

Maintained consistent metrics (process capability, control charts, measurement quality) for monitoring systems effectiveness

Achieved increase in Surface Mount Technology production yield from 70% to 95%

HAWKER BEECHCRAFT CORPORATION (Now Textron Aviation) - Wichita, Kansas Sept 2012-Aug 2013

Senior Powerplants Engineer (Contract position)

Analyzed test data and authored powerplant compliance and certification reports for nacelle cooling, engine operability, starting, systems safety (per MIL-STD-882D), weapons compatibility, and fire protection in support of AT-6C Light Air Support certification program.

HONEYWELL INTERNATIONAL – Phoenix, Arizona Sept 2000-Jun 2012

Engineer Jul 2010- Jun 2012

Provided guidance regarding specification interpretation in support of global printed circuit board design teams. Supported harmonization with IPC, ISO and Nadcap standards, including AS9100 and ISO 9001 compliance. Analyzed product specifications for clarity.

Operations Advanced Manufacturing Engineer (Quality Improvement) Mar 2009-Jun 2010

Led investigations into product yield and quality issues and developed focused process and design improvement project plans for new and legacy products. Functioned as Project Engineer/Manager for projects correcting manufacturing process issues. Used standard Quality Management and problem-solving tools such as SPC, control plans, 8D RCCA, 5-Why's, GD&T, and FMEA's.

Led team that collected and analyzed SPC quality data to find and validate top failure modes with Design for Manufacturability analysis tools, and identified top problems causing inventory/delivery issues

Responsible for communication to senior management for IPDS phase gates for each project

Generated savings in excess of $2,000,000 in reduced Cost of Poor Quality by leading root cause and corrective action and continuous improvement efforts on circuit card and printed board assemblies and manufacturing processes

Manufacturing and Quality Engineer Mar 2004-Mar 2009

Coordinated cost reduction, product improvement, outsource and factory relocation activities in support of functional transformation. Functioned as a project engineer. Re-created tooling and manufacturing processes. Interpreted and updated drawings and schematics.

Interacted with global suppliers to identify quality improvements and establish feedback with manufacturing and development personnel

Provided technical support for supplier development and manufacturing transition activities

Collected and updated necessary product information, Quality and manufacturing data and work instructions from corporate data systems to enable successful offshore and outsource transitions and First Article Inspections

Reverse engineered legacy parts and tooling, preparing Engineering Change Requests as necessary

Resolved obsolescence issues, including components and technologies, as required to support production and test

Determined Export Control information for technical data and factory tooling to prevent violation of ITAR

Led incorporation of avionics chassis design changes resulting in significant production cost-reductions

Drove division approval of new wire vendor resulting in a $500,000 annual reduction in cost of materials

Advised procurement team regarding vendor capability issues

Senior Engineer Sept 2000-Nov 2003

Performed turbine engine performance and modeling activities including development, certification and production support. Created key portions of automated performance check for use on T800 engine for RAH-66 helicopter. Authored Engine Starting sections of Operating Instructions for AS907 and AS977 turbofan engines. Earned Design for Six Sigma Green Belt.

BOMBARDIER LEARJET INC. - Wichita, Kansas - Aug 1990-Sept 2000

Engineering Specialist

Led propulsion activities in support of development, certification, and entry to service processes for the Learjet Model 60 and Model 45. Coordinated technical details with internal and external engineering organizations. Specified, evaluated and documented system and flight tests. Evaluated system integrity and conducted trade studies related to performance.

GULFSTREAM AEROSPACE CORPORATION - Savannah, Georgia - Nov 1985-May 1990

Propulsion Engineer

Responsible for engine performance activities related to development, certification, and support of Gulfstream aircraft. Re-established Secret security clearance. Participated in initial development of analytical techniques for engine trend and limit monitoring. Presented weekly windshear recognition and recovery briefing to crews attending recurrent training on site.

GENERAL DYNAMICS/FT. WORTH DIVISION - Fort Worth, Texas - Jun 1983-Nov 1985

Engineer

Analyzed afterbody integrations of advanced aircraft configurations. Conceived, planned and assisted in conduct of a wind tunnel test for those configurations. Obtained Secret security clearance.

EDUCATION

Texas A&M University - Bachelor of Science in Aerospace Engineering

CERTIFICATIONS AND TRAINING

EIT

Six Sigma Greenbelt

IPC J-STD-001E and ES Solder

“DO-254: Certification of Complex Electronic Hardware” Honeywell Training Course

COMMUNITY

Former Member and Vice-Chairman of Scottsdale Airport Advisory Commission

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