Manufacturing Engineer, Program Management

John Fales

**** ****** ***, *** *******, CA *****

Cell 323-***-****

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

EDUCATION

University of Southern California

• Bachelor of Science in Aerospace Engineering

United States Air Force

• Aircraft Technical Specialist

QUALIFICATIONS

• Experience in managing all aspects of manufacturing within AS9100 such as planning and coordinating manufacturing processes, planning work force and work flow, estimating production lead time and required staffing, budgeting and review of purchase orders.

• Complete understanding of MIL-STD-ASME Y14.5 and GD&T.

• Acting liaison between all departments including engineering, quality control, planning, purchasing and operations. Direct contact with customers, suppliers and vendors.

• Broad experience in composite design, lay-up and cure such as mold vacuum bag and resin infusion.

• Supervised and monitored clean room operation.

• Working knowledge with sheet metal forming and fabrication including TIG/MIG welding, material processes such as heat treating, plating and coatings.

• Experience in machine shop practices such as milling, turning, surface grinding, watejet cutting and EDM.

• Proficient in taking projects from concept to delivery in timely and cost-effective manner.

• Knowledge of Lean Manufacturing and Six Sigma.

• Experienced working in a fast-paced manufacturing environment with strong communication and interfacing skills.

• Self-motivated and able to work independently in support of product development and manufacturing. • Computer literacy in MS Office, AutoCAD and SolidWorks.

• Ability to obtain secret clearance with the Department of Defense.

WORK HISTORY

PPG Aerospace

Manufacturing Process Engineer (contract) 3/2020-5/2020

• Develop and validate process for new product launch.

• Conduct process time studies and process improvement.

• Revised and updated manufacturing travelers.

• Responsible for documenting PFMEA, RCCA, and Bill of Materials (BOM) for existing and new product line.

• Support tooling modification and validation.

• Participate in daily progress meetings.

• Publish weekly progress reports to management.

Avibank

Manufacturing Engineer (contract) 12/2018-7/2019

• Create and update process routings for manufacturing using MRP system.

• Develop new and approve existing costing for product manufacture. • Inspect and evaluate production tooling and recommend corrective action as necessary.

• Participate in PDR and CDR for new or revised engineering drawings.

• Support quality by providing disposition for rework instruction and corrective action.

• Design and implement safety equipment for machine tool loading.

• Work closely with and support production controll, purchasing, first article inspection, and tool room.

Dynamic Research, Inc. 3/2017 – 8/2018

Manufacturing/Production Engineer

• Managed day to day operation and supported programs from conception to delivery. • Purchase order preparation for material and vendor sourced parts.

• Planning and scheduling work load.

• Conducted vendor parts receiving and first article inspection.

• Process and fulfill customer orders for spare parts and assemblies.

• Support production, streamline, improve and participate in assembly as required.

• Provide detailed work instruction for product assembly.

• Perform and document final inspection prior to shipment.

International Composites Technologies, Inc. 4/2008 – 12/2016

Manufacturing Engineer

• Managed multiple programs with responsibilities for manufacturing engineering, production planning and scheduling, materials purchasing, quality control and tooling design.

• Created or updated manufacturing travelers and managed all documentation control and process per customer

specification.

• Performed root cause and corrective action on parts and processes that are not in control to drive down cost.

• Provided technical support in troubleshooting existing manufacturing processes to improve efficiency.

• Provided labor and material costing for multiple projects.

• Employed Lean Manufacturing and Six Sigma to improve product quality and reduce rework or scrap.

• Involved in day-to day support of production team including employee training and assistance as needed.

• Designed, built and tested tooling to improve production efficiency and reduce re-work or scrap of parts.

• Assisted in quoting new projects, reviewed purchase orders, and tracked material purchase and inventory.

• Headed projects such as the aircraft ballistic cockpit doors, composite panel assembly, and bomb resistant container assembly.

Lisi Aerospace Hi-Shear Corporation 6/2006 – 1/2008

Senior Product Engineer

• Responsible for tracking and reporting engineering group activity to VP of Customer Support. This included weekly reports and bi-monthly teleconference with regional salesmen.

• Position included R&D of new aerospace fasteners and related product, test lab support and sit on MRB team.

• Supported production to ensure product is built to specification.

• Working knowledge of lean manufacturing and Statistical Process Control (SPC).

• Completed design of blind threaded lock bolt for composite application and blind grounding stud.

• Advised and participated in all phases of manufacturing and testing of components.

• Coordinated with machining, heat treatment, surface treatment, and test lab departments during new product qualification. The team has successfully qualified several specialty fasteners for Boeing’s 787 program.

Northrop Grumman 5/2004 – 5/2006

Lead Design Engineer

• Member of IPT, supported the F-35 program by developing and designing a test fixture for inlet duct qualification from layout phase to final assembly following a strict timetable.

• Working with NC programming, manufacturing engineering, machine shop and assembly line.

• Additional tasks involved design changes of aircraft substructure and small parts using CATIA V5.

• Thorough understanding of mil specs and processes.

• Provided extensive procurement and supplier support.

• Good working knowledge of Product Data Management (PDM) application.

Telair International 2/1994 – 4/2004

Senior Design Engineer

• Headed R&D on the ballistic cockpit door developing procedure for lay-up, curing and cutting of the panel. In five months successfully built, tested and certified a ballistic panel to NIJ (National Institute of Justice) level 3.

• Subsequently received a patent as a co-inventor and secured a contract with Simair for ballistic cockpit door panels.

• Participated in the design, development, construction, and testing of the HULD (Hardened Unit Load Device) container (bomb resistant container).

• FAA conducted and approved the six months in-field test of the container.

• Responsible for development of in-plane telescoping loading system comprising of full aircraft integration and electro-mechanical design and installation.

• Established design criteria, prepare layouts and provide detailed production drawings.

• Interfaced with manufacturing, sales, and machine shop throughout fabrication and assembly of the system.

• Provided on-site technical support for the installation of the loading system in the aircraft.

• Have broad knowledge of sheet metal forming, castings, and extrusion design.

• Prepared illustrated parts catalog and repair manuals for new product line, conduct hardware tests and submit reports.

• Additional projects included design of cargo restraint netting and variety of standard aircraft cargo containers.

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