Design Engineer

Christopher Sackman

Wichita, KS *****

*************@*****.*** 316-***-****

Design Engineer

Progressive success at Spirit Aerosystems for 10 years, specializing in the structural airframe design of commercial aircraft and aviation systems. Expertise in quality, design for producibility and design for cost. Extensive structural design experience across the entire product life cycle from conceptual development to in-service fleet repairs. Notable background in team leadership, quality improvement and cost control results, aiding organizations needing quality outcomes within strict regulations, schedules and budgets.

Highlights of Expertise

Structural Design & Quality

Project Management

Root Cause Analysis

Tooling Requirements & Designs

Process Improvement

Dimensioning and Tolerancing (GD&T)

Aircraft Production Environment

Corrective Actions

Collaborative Teamwork

Communication Skills

Career Experience

SPIRIT AEROSYSTEMS, Wichita KS 2007 to Present

Sub Lead Design Engineer 777X (2014 to Present)

Oversee a team of 8 design engineers developing the side panel structure for Boeing’s 777X. Research and analyze customer design proposals and requirements in order to develop Engineering work statements. Collaborate with the customer and Supply Chain Management (SCM) to develop drawing release schedules, which support detail part fabrication, and the production line. Use Earned Value Management (EVMS) to track cost and schedule performance indexes (CPI and SPI). Provide technical guidance on all aspects of structural design from material selections and manufacturing processes to 3D model and 2D drawing creation. Analyze engineering layouts for conformity to design and drafting standards, design specifications, best practices, critical interface integration, producibility, and dimension and tolerance accuracies.

Supervise Spirit’s 3rd party engineering partner Infosys.

Reduced Spirit’s 777X production cost by 7% and weight by 7% while serving as the DtC (Design to Cost) Subject Matter Expert (SME).

Created an improved Engineering design layout process for 777X; reduced necessary layout development effort by 15%.

Served on the multi-discipline team that developed standardized quality checklists utilized by Design Engineering across the company; reduced engineering errors by 20%.

Led the effort to develop a cross discipline rotation program for new graduate engineers.

Worked on a small team to establish the knowledge and training requirements for all six levels of Design Engineering, utilized to determine promotions and career progression.

Mentored 3 interns and 3 experienced engineers.

Granted the VP of Engineering’s Special Achievement Award.

Lead Design Engineer KC-46 Tanker Shipside Support (2013 to 2014)

Supervised 3 design engineers in support of the production line during the first 4 KC-46 Tanker units. Led the engineering liaison effort to support fabrication, assembly and installation with the product line. Reviewed preexisting nonconformance backlogs in order to correctly classify discrepancies. Coordinated with Material Review Board (MRB) engineers on new discrepancy dispositions. Provided engineering support for quality audits and first article inspections. Evaluated and resolved production problems and reduced assembly time by developing new production processes and procedures that better utilized manufacturing capabilities.

Reduced preexisting engineering error backlog by 30% by identifying the type and cause of errors, errors previously charged to Engineering.

Spent 2 weeks on-site with a key Spirit Supplier in order to develop a new build plan after failure to meet schedule and quality expectations.

Selected, for the 2nd time, to be Spirit’s on-site Engineering representative at Boeing’s facility in Everett, WA supporting final assembly, flight test and certification activities.

Led the effort to have all engineering errors corrected by the 4th KC-46 Tanker unit.

Recognized by the VP of Engineering with a Special Achievement Award.

Sub Lead Design Engineer KC-46 Tanker (2010 to 2013)

Supervised 10 design engineers in developing the Cab and Main Deck Floor structure. Created engineering layout and release schedules to track and provide management with updates on progress. Evaluated internal and external trade studies and determined work statement impact. Provided product enhancements with the development of new GD&T methods for the Main Deck Floor seat tracks. Managed engineering change logs and worked with the program Review Board to get engineering changes approved and incorporated.

Released designs on time while 70% staffed; led to 25% non-recurring budget savings.

Developed new tooling necessary for the installation of new seat tracks and Tanker unique structure.

Revised specifications of two source control drawings; enabling procurement from multiple vendors, significantly reducing costs.

Mentored 3 interns and 3 experienced engineers.

Structural Design Engineer (2007 to 2010)

Designed fuselage structure and engineered designs for: Boeing 737, 747, 767, 777 and KC-46 Tanker. Developed and reviewed engineering drawings, bill of materials, manufacturing specifications and processes. Integrated primary airframe structure and aircraft systems, e.g. Wiring, ECS, Electrical and Payloads and Flight Controls. Ensured Spirit’s designs satisfied Boeing, FAA (CFRs/FARs), manufacturing, and reparability requirements and regulations. Performed GD&T studies on new and existing structure to prevent issues. Conducted anomaly investigations and performed root cause analysis.

Released all engineering designs ahead of schedule.

Served as the design engineer on Spirit’s first Shipside Support team providing engineering support in the factory for the first 3 747-8 Passenger units.

Appointed as a Subject Matter Expert (SME) on the CATIA V4 to V5 transition team; converted Spirit Engineering over to CATIA V5 within eight months, 5 months ahead of schedule.

Selected to be Spirit’s on-site Engineering representative at the Everett, WA Boeing facility during the final assembly of the 747-8.

Education & Credentials

Bachelor of Science in Aerospace Engineering

University of Missouri-Rolla, Rolla, MO (2007)

ABET-accredited aerospace program

Technical Proficiencies: aPriori, C++, CATIA V4, CATIA V5, Enovia, Matlab, MS Office (Word, Excel, Access, PowerPoint, Project), PDM, SAP, UNIX

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