Robert Lee Washburn

****Cerullo Rd

Oak Harbor, WA 98277

206-***-****

SUMMARY:

An individual driven by goals and results; capable of creating both computer-aided designs, and hand-build items that are accurate, durable and user-friendly. Professional responsibilities have included development contributions on a broad range of components and systems for missiles, drones, airplanes and helicopters, and pilot experience has included both fixed-wing and rotorcraft.

Notable demonstrated abilities include collaboration, interpersonal communication, and cost-savings strategy development and deployment. Effectively conversing with any level of technical and managerial personnel while retaining confidence in the strategy and decisions at hand allows for real headway towards real results. Since cost-efficiency is so critical to the success of any project or program in the commercial aerospace industry, the ability to think outside the box to realize opportunities that re-purpose and reuse existing concepts, designs and equipment to achieve equivalent results is valuable.

To Summarize; I have been working in the Flight Controls organization, both Primary and High-Lift Systems for over 29 years (110) months. Designing, test equipment, test procedures and developing new testing technologies that are being incorporated in the Certification Testing for the new 777X aircraft families.

CATIA V5 +10K Solid Works +4K ENOIVA, Excel, Project, Word, Certified TRIZ Practitioner (theory if inventive problem solving) 120 Hrs. (UCLA). Advanced Hydraulics 96Hrs. Flight Systems Test Equipment design 6 Years.

PROFESSIONAL EXPERIENCE:

Boeing Assignments

Jan 2019 to June 2020

NMA program, Pilot Controls

Support design development of the Primary Pilot Controls for the NMA program

Dec 2017 to Dec 2018 777X Flight Controls High Lift Test Support

This year was made up of supporting FAA Testing of the High Lift Equipment at test facilities in Germany, India and the USA.

Sept 2016 to Dec 2017 15 Months 777X Flight Controls High Lift Test Team (Iron Wing, ITV HL Rig, and Component Certification Testing)

oEffectively managing High-Lift (HL) systems, configuration controlled CAD data sets, parts list between Boeing and its European supplier.

oChampioning cross-team coordination between Boeing and its European supplier during weekly supplier meetings.

oSupporting engineering team by preforming model investigations to resolve emergent questions and issues.

oActively contributing to leadership strategic initiative to reduce cost and compress schedule on HL component-level testing.

oBCA Focal for collaboration with Boeing-Russia in Kiev, Ukraine and Moscow, Russia. Providing BCA guidance for rig design.

oDeveloping RFPs for HL build-to-print component certification test supplier selection, and ensuring all Boeing supplier management (SM) processes and procedures are followed.

oLeveraging all opportunities to reduce costs through innovation and rethinking development of the HL test program.

oAR test witness certification complete.

Oct 2015-Sept 2016 12 Months 777X High-Lift Torque Tube Drive System

oCreated and released NRPD layouts, detailed drawings, and other required releases throughout the detailed design process.

oServed as one of the designers creating the detailed design definition of the High-Lift Torque Tube System.

oActively mentored intern on Boeing processes and procedures and sound engineering practices.

Jan 2015 to Oct 2015 10 Months 777X Folding Wing Tip System (EHSV Test)

oOversaw risk reduction through engineering testing on a technical solution new to the industry: closed loop position based control of a hydraulic motor with an EHSV.

oPlanned a test (via WSRD) to utilize a decommissioned test rig, recycled hydraulic components, and borrowed test and systems equipment from multiple organizations to perform engineering testing on a limited budget.

oProposed said plan to upper management team and secured funding to move forward.

oCollaborated with Actuation System Analysis, the Product and Development team and Lab Mechanics to put the above rig together for less than $90K in 30 days.

oDeveloped and executed 614 DTPs over six weeks.

oCreated code source that later was used as a baseline for articulating the prototype Folding Wing Tip.

oAccomplished all test program objectives for exploring control of a Hydraulic motor with an EHSV (never been done in the industry) while spending $80K less than the $300K budget; 60% less than earlier projected cost for this test.

Oct 2012 to Dec 2015 37 Months 777X Folding Wing Tip System (Pin Insertion Test)

oGenerated CATIA models to support different configurations in the early days of Folding Wing Tip System (FWT) development.

oEffectively supported cross organization collaboration in multiple workshops.

oNegotiated with the Museum of Flight to gift the original 777 folding wing tip test rig back to Boeing at no charge as a cost-savings opportunity for FWT testing.

oWorked with Boeing Legal to successfully clarify how to collaborate with foreign suppliers regarding a project with Export Controlled aspects.

oSupported the test team by way of model coordination with Structures and construction support at the Lab.

oDeveloped and ran 500 + DTPs for the pin insertion test.

oReconfigured raw test data to usable test data to support the test reports.

oCompleted 120 hours of classroom training to acquire the certification of TRIZ Practitioner from UCLA.

oCompleted a 28-hour Boeing Advanced Hydraulics class.

Oct 2009 to Oct 2012 36 months 777X Folding Wing Tip Development

oJoined the Product and Development team for the up and coming 777X under Mr. Randall Britts.

oStarted on the Folding Wing Tip project.

oDistilled multiple designs into a firm configuration.

Dec 2007 to Sept 2009 767 Tanker Program

oSpatial Integration for the 767 Tanker Program.

oGenerated and executed a schedule to populate High-Lift models into 767 Architecture.

oReused V-4 models versus modeling new V-5 models to populate ENOVIA reducing projected costs by 600 hours.

oAsked to populate ENOVIA with High-Lift equipment on Tanker program by end of January, 2009.

oFloated a plan past my peers but was told it would fail.

oWent to the Drafter Development team and recruited 7 brand new drafters to do the modeling of the class 1 solids and located them in space to support the Spatial Integration side of the project from mid-December to mid-January.

oFinished ten days ahead of schedule.

oProduct and Development took two of the new drafters, based on their performance, and used them on the early days of the High-Lift 777X development.

oPICP tasks and designed the inboard vapor seal on the 747-8.

oWorking with High-Lift lead, completed a flap kinematics investigation.

oSuccessfully completed the inboard trailing edge torque tube re-route on the 747-8.

Nov 2005 to Sept 2007 747-8 Program

oDesigned cable runs in Primary Flight Controls for the 747-8 freighter and 747-8 Intercontinental.

oInvestigated rotor burst and tire burst scenarios for the safest cable path.

oManaged multiple drawing packages for the team in Russia.

oWorked on spatial integration issues and drawing releases for the 747-8.

Previous Employment

Oct 2004 to Jul 2005 CNA Manufacturing, Woodinville, WA

oWorked on tool design, multi-configuration holding fixtures for trimming and drilling composite parts.

Mar 2004 to Sept 2004 Boeing Commercial, Tulsa, OK

oWorked on composite tool design to support the X-45C UCAV program.

oDesigned Lay-up tools and Bond and Assembly fixtures for the wing.

Jul 2001 to Mar 2002 Boeing Commercial, Renton, WA

oWorked on the 737 Flight controls Platform Team.

oCAITA modeling and drawings.

oMy time was cut short due to 9/11.

Oct 2000 to Jul 2001 Boeing Commercial, Everett, WA

oWorked in Flight Controls, High Lift.

oSupported the 777 and 747 programs with CAITA modeling and drafting.

Jul 1999 to Feb 2000 Pacific Aerospace and Electronics, Wenatchee, WA

oDeveloped new markets to feed their manufacturing and fabrication divisions as a sales engineer and program manager.

Feb 1998 to May 1999 Hexcel Structures, Kent, WA

oWorked in sales and marketing to develop new customers.

oSold engineering, tool design, and aerospace structural components.

oDid market research, prepared and presented detailed presentations to director level and above on potential sales campaigns, i.e. blended winglet for the 737.

oWorked with Aviation Partners and sold the engineering and tool design for the original 1st ten ship sets for $10M.

oSold the wing to body landing gear doors and nose ray dome to Sino Swearingen Aircraft, San Antonio, Texas for $23M.

Mar 1997 to Feb 1998 15 Months Lead Tool Design Aim Aviation, Renton, WA

oWorked as a Lead tool designer on 747-300 package for KLM.

oDesigned all of the interior tools, developed work cell layouts, and managed the drawing package and the NC programming to support the reconfiguration of a group of 747-300 for KLM.

o Supervised 5 tool designers and 3 NC programmers to completion.

oSupported and worked with KLM on the onsite installation team in Singapore and Amsterdam.

Feb 1996 to Mar 1997 Boeing Commercial, Renton, WA

oWorked as a tech designer, drafter, checking solid models for accuracies for GRA and angle gear boxes.

oMoved to tool design to support the 737-700 assembly line, wing to body joint.

Feb 1995 to Nov 1995 Aim Aviation, Renton, WA

oDesigned and Developed tools for the interior mock-ups for the DC 9, then pushed the interior into production for customer, Northwest Airlines.

oWorked on the tooling family and the manufacturing process work cells for the DC 9.

Apr 1992 to Feb 1995 Boeing Commercial, Wichita, KS

oDesigned tools for assembly fixtures, 777-200 struts and thrust reversers for the 777-200.

oDesigned the engine cowling tooling for the 737 NG.

Aug 1990 to Feb 1992 Heathtecna Aerospace (Hexcel), Kent, WA

oBuilt master models that replicated 737 Canoe master models.

oBuilt master models and lay up tooling for Airbus 340 landing gear doors.

oMoved to their R & D lab to design and build tooling to support the engineering and design of the Dennis Conner America’s Cup keel.

oJoined the engineering staff and acted as a liaison with manufacturing and engineering

to support the McDonnell MD 11.

Sept 1988 to Apr 1990 Kaman Aerospace, Moosup, CT

oBuilt master models and trained two direct employees on building and setting up master models.

Jun 1987 to Aug 1988 McDonnell Douglas, Huntington Beach, CA

oWorked as Lead of second shift test lab on Titan 4 missile payload bay launch test fixture.

oWorked on payload bay fixture for the Delta missile and on holding fixture for the Dart Program.

Oct 1986 to Feb 1987 Tracor Aviation, Santa Maria, CA

oBuilt master models for E2C Engine Nacelle intake ducts.

May 1986 to Oct 1986 Northrup Ventura, Newbury, CA

oBuilt master models for wind tunnel testing of one subsonic and one supersonic drone.

oReworked the router fixture tooling of inboard leading edge of the B2 Bomber, inboard to mid-wing.

Aug 1985 to Feb 1986 Flamco Engineering, Odgen, UT

oReviewed the progress of tooling packages for Bell Helicopter for improvement.

oCreated 7 master models to bring them back onto schedule.

Feb 1985 to Aug 1985 Bell Helicopter, Textron, Fort Worth, TX

oWorked on engine nacelle intake master models and blade compression tools for the Osprey Tilt Rotor Aircraft.

oAsked by Bell Helicopter to go to Flamco in Utah to work a tooling package that appeared to be in trouble.

Jun 1984 to Dec 1984 Grumman Aerospace, Bethpage, NY

oModeled concept models for wind tunnel testing.

oReworked the assembly fixture for the space shuttle rudder.

1977 to Jun 1984 Nordam, Tulsa, OK

oCompleted a 3-year apprenticeship program with master tool builder, Eddie Dodson.

oWorked on Pattern-making, lofting, jig and fixture, lay-up tools, match-mold dies.

oCompleted interior tooling family for 747-300, Sikorsky S76 Helicopter, Bell Jet Ranger, Falcon Business Jet, Lear 24.

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