PERSONAL SUMMARY

An Aerospace Structural Foreman, Process Engineering Experience, Process Consultant, Complex Assembler experience and Team Leader with hands on Industry experience. Experience includes Research and Development, Continuous Improvement Leader, parts and Assembly tool design, Engineering Processes and Manufacturing to aircraft structure specifications for military and commercial aircraft. Extensive experience in aircraft structure details and standardized process formation. Successfully worked on engineering projects, controlling them in terms of time, cost targets and quality. Therefore ensuring that project tasks are correctly interpreted, planned, delivered on time to internal and external customers specifications. Bosch North Charleston SC.

Maintenance Mechanic

Job duties on test line. Maintain equipment TPMs, troubleshooting and repair equipment from SOPs on high pressure hydraulics systems, low pressure systems, air and low voltage electric systems. PLC systems. I calibrated test line EMIs and ran diesel fuel injectors product to Bosch and customers specifications. June 18

th

2018 – April 1

st

2022.

Craftech Incorporated

Hudson N.Y.

Apprentice Tool And Die Maker November 11th - August 26th 2017 Injection Mold Tool and Die Making. Job duties included Operating Monarch VMC 75B 3 Axis CNC Mill / Chevalier Surface Grinder NC / Alpha 400 Engine Lathe NC. All Machine shop standard practices and equipment.

Chipton Ross ( Boeing S. C.) South Carolina

M.T. ( Manufacturing Technician ) November 6th – May 9th 2016 Job duties included Assembly of 787 Dreamliner. Installing Main Landing Gear, Hydraulics Assembly, Swedging, as well as 16 Certifications. Alpha Sheet Metal South Carolina

Brian C. Backis

Cell: 843-***-**** Email: ad3mqi@r.postjobfree.com Sheet Metal Fabricator / Machinist April 27th - November 15th 2015 Job duties included Machining and Fabricating Military Details and Assemblies as well as Boeing projects.

Ducommun Aerostructures New York

Level 3 Foreman/ Processes Expert March 14th- 1994 – Sept. 19th- 2014 Working on Aerospace structures for 20 + years as a Brake Press Forming Operator, Journeyman Machinist,Team Leader, Sheet metal Process Expert and Protype part development .Value Stream Mapping, Six Sigma projects, Reverse Engineering, Manufacturing Engineering, Process Engineering Experienced and Tooling Design. Brake Form part process creation, manufacturing and producing hands on to all customer tolerances and specifications.

Troubleshoot processes, providing innovative solutions and interprets complex blueprints, customer drawings, mylars, specifications and other inspection media.

Performs complex multi bend process (standard and tight tolerances).

Verification qualified (set-up process and quality assurance).

Proficient many types of measurement techniques.

Creates, reviews and approves Standard Operating Procedures (SOPs).

Involved in working on research and development parts and processes Train operators on complex processes and process theory.

Follow customer specifications and requirements on all processes.

Working in a safe manner in order to satisfy Health and Safety legislation. KEY SKILLS AND COMPETENCIES

Complex problem solving ability using Six Sigma

Proven ability to lead team to successful training and execution of of responsibilities as well as independent growth of team members.

Research and Development (process development).

Works well as a part of a team and have the ability to take on a strong leadership role.

Reverse engineering.

Tool design and creation.

Continuous improvement of processes streamlining to a fast repeatable process with low or zero scrap yield.

Ability to work to tight deadlines and under pressure as part of a team.

Working knowledge of fatigue and crack growth analysis of metallic structures.

Excellent communication and instructional skills.

Actively supporting and promoting continuous improvement.

An ability to manage multiple tasks.

Possessing the drive to follow tasks through to a successful outcome.

Able to work to an agreed time scale.

Continuously developing engineering skills and experience while working on projects. Qualifications Profile

Employed as a Level 3 Brake Press Foreman with Ducommun AeroStructures and Assembly Solutions

Twenty years + of AeroSpace experience in Process Engineering, Team Leader, Level 3 Sheet metal forming,Journeyman Machinist, fabrication and building, complex Assemblies

Multiple positions, job duties and projects including:

30 years of metal fabrication

21+ years of Aerospace sheet metal engineering, fabrication, assembly,and machining

Technician (Process Expert, Consultant) Brake forming, Hot sizing, Stretch form, miscellaneous forming.

Quality Verification,QMAT Auditing

Team Leader for 10 years, 3 Departments, 15 men total Staff skill development and trainer.

Process Developer, Designer

Various forms of hot and cold formation

Value stream mapping

Project development and design, Lean Manufacturing

Six Sigma Projects ( Continuous Improvement ) SPC, GDT, AS9000, ISO9001 Standards

Research and Development new parts, Engineering Process Development

Reverse engineering for design improvement

Engineering, support and consulting on new parts, processes, meet with Customers

Develop standardized operation procedures ( SOP ) creation

Design project tooling (joggle Dies, fixtures, shop aides, fiberglass tooling and lay up)

Building Assemblies to Customer Specifications, GDT, SPC Education and Credentials Columbia-

Greene Vo-Tech Center:

Greenport, N.Y.

Welding/Machine Shop I and II 1985-87 2

year Trade school

New York State Department of Labor Apprenticeship Training: Machinist/Sheet metal Fabrication to Aerospace Specifications Dynabil sponsored 1996-99

4 year Certification

Memberships ASQ My Experience Highlights

• Privately owned and operated machine shop business for 10years

• Star performer three times at DBI and Ducommun.

• As a team leader, my areas 3 departments, received Gold Status from Boeing for quality and on time delivery by exceeding production goals

• Developed bending, Process Development (50 channels times six bands each 300 bands daily +/- .030 on flange 017 on channels). These were ATA channels with full size holes for direct install to aircraft. Profit increase for lean manufacturing production was 30% Approximate savings were $30,000 a year.

• Six sigma.I Created and developed a value stream Continuous Improvement for bending six bend channels produced 24 channels a day 4’ to 7’ in length +/-0.10 tolerance on channel. Individual operators average was 7 channels complete a day. With the Process Improvement I developed two operators working together could improve by each operator could make 12 a day 40% improvement for each operator( x2 collectively) Each channel cost approx.$800 . That's an additional $8000.00 to production per shift X 3 shifts $24,000 day potential improvement.

• Six sigma process reduction project ( Joggle Tooling Modification ) saved 40 min. per part, on a 43 min. previous process. There are 8 channels that get joggled in each kit, x 3 kits a week equals 24 channels x 40 minutes savings on each joggled channel. Savings per week in time and resources is 16 hours. This design improvement is used for all Joggled Channels and also now is Standard practice for tool design through out Ducommun Aerostructures N.Y. (all joggle tooling) And theory with other tooling as well.

• Reverse Engineering of Black hawk firewalls/ Sea hawk firewalls. I had a key role in all aspects of Redesign, part attributes, process development, tooling, inspection tooling and criteria, process formation and development of parts, SOP's creation, and Technical training to Operators. We have been making these Firewalls for a long time and they are a major contributor to Ducommun's income. Also Comanche firewalls as well as other programs, Military and Commercial aircraft.

• Well rounded in Design, Engineering, Processes, Training, Customer Specifications, Quality, Inspection, Auditing of Processes and Fabrication

• Developed Joggle Adaptive Tooling for different machines for demand capacity

• I sat on the SPC Panel at Dynabil Industries for 3 years. Quality projects included employee training on SPC, Process Analysis, Process Analysis Tool Applications Gauge R+R, Process Troubleshooting, Repeatability Analysis

• First piece qualified to approve part runs to Engineering, Quality specifications, SPC and Customer Requirements since 1996.

• Built Assemblies, Stretch form Operator and Heat Treating Operations, Machine Shop Tooling Technician, Pattern Shop Technician.

Special Projects

120 Tubes Sikorsky Boeing Osprey – Problem part to for Sikorsky and two other companies to fabricate. I engineered and physically developed part process. The outcome was a good finished product, a repeatable process to all customer specifications and requirements. The profit percentage was 45%. Profit exceeded our anticipated amount. 30% was the anticipated margin, by an additional 15%.The quality outcome exceeded customer expectations due to prior fabrication history.

• Boeing Osprey -147/-148 Details – Problem part to for 3 companies to fabricate. I engineered and physically developed part process. The outcome was a good finished product, a repeatable process to all customer specifications and requirements. The profit percentage was 45%. Profit exceeded our anticipated amount. 30% was the anticipated margin, by an additional 15%.The quality outcome exceeded customer expectations due to prior fabrication history.

• Trained under Master Tool and Die Maker building Sikorsky S-76 Firewall Assembly Fixture. The outcome was the finished assembly that met all customer specifications and requirements. We also collaborated with the assembly team involved to build the assembly and I myself bending the details to fit tool,engineering new details dimensions and process development. I wrote the Standard Operation Procedures

(SOP’s) for all details and fabricated Operator training for a repeatable, streamlined manufacturing process.

• Six Sigma Joggle Tool Project – Joggled Channel Hot Formed Tooling Process Improvement. Joggle Channel rework times were 45 minutes per channel to handwork to meet customer requirements. I experimented by machining an old Joggle Channel tool machining it deeper by + .055 thousandths. By going deeper, out of tolerance with anticipation of spring back, parts joggle came out to Customer Tolerances. We went from 45 min. per part rework to 2 minutes, saving 42 minutes on rework. We did a few more tools, and the rest is history. This design ( spring back ) Joggle improvement is epic. It is used on new and old tooling; clips and channel tools and is

( standard DAS adopted )

• Six Sigma ( Set Up Verification Process ) Basic function is Scrap Reduction, Machine Setup Standard, S.O.P. and Operator Process Discipline – a proven and adopted practice, this verification process used properly, decreased scrap overall by 98% with 3 experiments I conducted. This Standard Practice was adopted by Dynabil Industries and DAS travelers since 2007 to present.

• Six sigma Part nesting . Frame which holds many pieces to be bent, opposed to bend one part at a time. Frame consists with information pertinent to correct process; part

#, bend direction, banking side for brake forming and also Non Destructive Center line bend touch point for correct dimensioning of bend location. These characteristics information on the frame reduces Operator mistakes greatly, reduces scrap loss and speeds up output by 90% because you bend multiple pcs. With one heating cycle Opposed to one at a time. It took 6 hours to bend 300 clips individually, to 1.5 hours in nest (Non Destructive Center line bend was adopted to Dynabil and DAS mylars )

• CH53K Prototype/ production parts. 10’ Skins program( Base Skin) multiple contoured skin, Lay out development for bend execution “ bump” roll process 5’ x 10’ 6-4 Titanium. 3 bend rolls formed. Done by eye. Parts bent successfully to +/- .020 on profile datum’s banking points Tolerance. 125K each. Bent 4 pcs. Successfully to customer specifications. On time delivery to customer. Short flow. Process Improvement I suggested to Engineering I.P.T. Group was to Index both ends of part for bend bump locations and hits ( bumps ) repeatable process for Lean Production. Boeing Programs

All programs single bonds to complex multiple bonding parts to tight tolerances, customer specifications and requirements.

727/737/747/757/767/777/787 Dreamliner/Boeing Osprey

Spirit Freighter

IAI

Korean Air

Spirit

(Most are 6 bend channels varying in length form 1’ to 10’ in length) Sikorsky Programs

576D firewalls Comanche firewalls

Apache prototype

CH53K Skin

UES Ducts

120 tubes

Canopy Skins

Black hawk firewalls

Sea hawk firewalls

-Reversed Engineering to Improve design per Customer request

-Research and Development

-Created new Assembly fixtures, shop aids

-Collaboration of Assembly new designs and processes

-Problem solve (troubleshoot design and process problems

-Created new forming process/brake forming process/tooling

-Bent and formed all details of new designs

-Developed all SOP’s (Standard Operation Procedures)

-Trained personnel on all forming process (how to build)

-Continuous improvement and SPC on all brake form processes

-Played a key role with Value Stream channels for Assemblies processes. Full Kit fabrication with Assembly Value Steam process.

Worked with Dynabil Engineers and Sikorsky Engineers with constant communication between sites for Reverse Engineering of Assemblies to Detail level and Redesign and build to Specification. Prototype Manufacturing Specialist responsibility. All aspects of forming and design processes were followed to all customer and industry specifications

Strong engineering background from hands on experience from working with these programs. Due to the demand in Dynbil’s fast growth of new contracts, I had the opportunity to work on engineering projects which enabled me to be responsible with part design, process, testing Research and Development to Customer Specifications.

All programs were a success for Dynabil and we obtained more contracts due to our skills and abilities.

ADDENDUM

Fabrication and Process Experience Overview

Aircraft detail manufacturing process

Complex Assembly Technician

Bench Working Alt Method

Bucking Rivets

Clean blast process

Deburring to specifications

Extension trim Form Joggle/Machine/Form press brake

Forming, Brake Press/bend/roll/bump/hem/stretch/shrink

Forming Roll-Hot Form/Cold Form

Forming, Rubber Press

Forming, Stretch Press

Hand Working

Heat Working

Hardness,conductivity testing

Hold Preparation

Identification

Joggling

Layout

Machining

Mechanical Press

Nibbling

Riveting

Routing

Shearing

Stress Relieving

Tool Tab trimming

Tube Working

Welding (Samples)

Welding (Seam)

Welding (Spot)

Weld tear testing

Welding, Tig

Aging wrought material

Solution Heat Treat

Supervision Aging Freezer

Engraving (Part Mark)

SPC Trainer

Gauge R+R

Tensile testing and strengths testing

Custom specifications /blue prints/Mylar’s

Tolerances

Part design

Reverse engineering

Trained operators on Brake, Joggle,Hand working, Flattening, Fabrication processes

GDT trained

Machine training operators machine theory teacher classroom training of students

ISO 9001

Working knowledge of specifications

Technician (Process Expert)

Kaisen

Lean Manufacturing

Complex Problem Solving

Set Up Verification

Value Stream Mapping

Quality Assurance

Hands on Training

Hot Brake forming

Team Leadership

Multi-task

Root Cause Analysis

Continuous Improvement

Process Improvement

Six Sigma Experienced

Manufacturing

Composites

Program Management

5S

Power Point

Microsoft Excel

Pattern Shop (Tooling, Layup)

Different Approach

Designed Tooling, Processes with or without Engineers

Blacksmith, Forging

Trade School

Salt Bath Heat Treating, Aluminum

Quench Processing, Aluminum

Aging Aluminum, Natural Processing

Aging Aluminum, Ovens Processing

Stretch Forming – Aluminum, Clad Aluminum, Stainless Steel Stretching, and Titanium

Properly identify material condition in Stretch Forming Process

Joggling Aluminum, cold, hot

Trouble Shoot Problem Processes ( hands on )

Read and interpret mylars, blueprints, drawings, customer specifications

Engineering Library utilization

Maintain and inspect equipment

Write Standard Operation Procedures

Created operator Formula for Brake forming

Operated Overhead cranes ( small and large track cranes, building length)

Fork truck experience

Machine experience - operate lathes. milling machines (horizontal, vertical) drill press, radial arm drill boring press( 12’ arm), vertical key way cutting machine, brake presses, single arm ram, 4 post press, Trumph press, Hufford stretch form press, Erco stretch form press. Aging ovens, electric high heat ovens, cold saw, horizontal and vertical band saws, spot welder, seam welder, power roller 8’-6’ etc.

Trained myself (self starter) in brake forming large titanium parts

Top level, level 3 brake form operator

Wrote many SOP’s for brake form area

Apache helicopter proto type parts dimensional forming

Key fabricator in reverse engineering, design, order and design .make tooling, process development, fabrication, SOP development and process standard of

Black hawk and Sea hawk firewalls

Shop aides design and creation

Short flow processes experienced

Value stream design and execution

Working team leader

Hot Sizing Titanium Team Leader

Hot/Cold Brake form A Hot/Cold Brake form B Team leader: Hot Titanium Processes as well as Cold forming Aluminum and Stainless Steel

Miscellaneous Form Team leader in Hot and Cold form Techniques Professional References :

Name Address Phone

Dennis Fitzgerald 344 W.157th Street Gardena CA. 310-***-**** V.P. Operations

Impresa Aerospace C.A.

Robert Casalino 2 Flint mine Rd. Coxsackie N.Y. 518-***-**** Business Development Manager

Ducommun Aerostructures N.Y.

Wesley Fitch 6 New St. Coxsackie N.Y. 518-***-**** Verify Source Inspector

Ducommun Aerostructures N.Y.

Mario Di Paola 2 Flint Mine Rd. Coxsackie N.Y 845-***-**** Project Engineer

Ducommun Aerostructures N.Y.

Joseph Bedani 25 Vermilia Lane Coxsackie N.Y 518-***-**** Assembly Engineer

Ducommun Aerostructures N.Y.

Almar Lal 2 Flint Mine Rd. Coxsackie N.Y. 607-***-**** Ducommun Aerostructures N.Y. Director of Operations

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