THOMAS MCCABE

**** ******** ***, ********* ******* 32934 Cell 386-***-**** admzqx@r.postjobfree.com

PROGRAM MANAGEMENT/PROJECT MANAGEMENT/Manufacturing PLANNING/AIRCRAFT NEW PRODUCTION/AIRCRAFT FIELD SERVICE

SUMMARY OF QUALIFICATIONS

LEANARDO DRS, MELBOURNE, FL 6/29/20 - Current

Operations Program Manager (Direct)

Point of contact accountable to Program Office and Management for all Program Operational requirements including, responsible for developing and executing plans required to meet or exceed all contract and Internal Operation schedules, develop and manage financial plans and forecasts inclusive of Revenue/Cash/Program budget management, strategically align master production schedule to level load factory capacity and streamline supply chain to support contract schedules. Responsible for new contract awards while aligning operational needs including production readiness, kick-off contract schedule review and approval, working with supply chain/buyers to create PO’s to validate material/equipment lead times while setting up facility to maximize production capacity. Operations leader for IPT accountable for Production Operations Management and risk/opportunities. Implemented production process and supply chain revenue enhancement in order to continue driving down operational cost. Held and drove process improvement kaizens/actions with the IPT team support in order to drive root cause corrective actions and corrective action implementation/flow down.

EMBRAER EXECUTIVE JETS, MELBOURNE, FL 1/31/11 – 6/26/20

Production Supervisor (Direct)

Supervised start up manufacturing of the Phenom 100/300 and Legacy 450/500 through Sub Assembly, Final Line, Paint, Interiors, Flight Preparation and Delivery. Supervised the First Article build cycle under FAA oversite while successfully obtaining Production Certification within one year of program kick off. Worked in parallel with Engineering, Quality and Material teams to certify Quality Manual, Production Process Flow, Create and Release Process Plan’s via FAI approval, Certify Local Suppliers and Critical Process Vendors, Implementation of Training and Employee OJT Certification Program, Rolled Out and Implemented Lean Process culture and Cell Certification achieving assembly line ramp-up under budget while achieved Program Mile Stones. Utilized Six Sigma tools, RCCA/5Y’s and Kaizen’s in order to improve processes, reduce waste and increase efficiency. Managed a team of up to 80 employees to assemble large structural components, wire harness/avionics install and test, hydraulic build up and function test, flight control install and rig, wing to fuselage/vertical tail join, Interior installation, Paint Process, First Flight through FAA/EASA/ANAC Certification Flight while interfacing with the Customer and Regulatory Groups through the Delivery Process.

BOEING AIRCRAFT COMPANY, EVERETT, WA 7/12/10 – 1/28/11

787 Flight Line Mechanic (Contractor-Planetechs)

Implemented structural modifications being incorporated with engineering changes due to fatigue and test flight data. Duties included drilling/reaming and repairing titanium and carbon fiber structural assemblies. Production encompassed completion and modification of partner (Alenia) production assemblies. Modified horizontal and vertical stab in accordance with CATIA-V and Planning Instructions. Provided technical data to flight line engineers regarding design changes, fabrication and installation issues.

BOEING AIRCRAFT COMPANY, Charleston, SC. 5/18/09 – 7/09/10

787 Project Manager (Contractor-Planetechs)

Project Manager

Managed project lifecycle, technical and functional aspects for Structures and Systems Integration projects. Provided interpersonal customer interaction and performed hands-on project control in order to meet cost targets and program delivery schedule. Carried out critical task planning, project scheduling, resource level loading, project budgeting and risk analysis. Held management meetings to discuss production issues and resolution, Program Performance KPI’s and overall project cost. Managed a highly skilled staff of Engineers, Planners, Supervisors, Leads and Technicians. Developed, analyzed and managed project critical path, schedules and resource forecasts. Investigated and offered options to resolve manufacturing and production issues. Organized and built support teams in order to achieve design changes while working in parallel with baseline production schedule. Created, reviewed and maintained policies, processes and procedures by coordinating with other organizations to support program requirements. Applied working knowledge of industry practices, techniques, and standards to achieve company goals.

NOMAD AVIATION, Sanford, Fl. 1/14/08 – 5/15/09

Production/PMA Supervisor (Contractor-Global Technical Services)

Supervised and Planned Production in all aspects of aircraft maintenance, repair and support. Initiated quotes/proposals to NAVAIR procurement officers to fix both structural and system discrepancies. Planned and Designed aircraft repairs while incorporating fabrication and installation instructions in accordance with DER approvals. Wrote Process installation instruction for the Pro-Line 21 airframe modification to the NAVY T-44. Planned system maintenance in accordance with Raytheon Aircraft Maintenance Manuals. Liaison between Program Management, Assembly, Contract’s, Manufacturing, Vendors and Engineering. Developed work statements and process flow with customers to develop schedules using various business systems to support delivery commitments. Created and maintained complex manufacturing plans, bill of materials, work instructions based on NAVAIR design requirements. Demonstrated successful budget and schedule completion of multiple full lifecycle Aircraft Modification Projects.

BOEING AIRCRAFT COMPANY, Charleston, SC. 5/21/07 – 1/11/08

Production Supervisor-Manufacturing (Contractor-Planetechs)

Supervised Production while participating in the FAA, First Article Inspection/Manufacturing and assembly of the first 787 fuselage join. Supervised the FWD joint line assemble 43FWD Cabin Section to 11/45 Wing Box. Planned daily production targets, ensuring key tasks were completed with zero defect. Planned flow strategy and implementation of six sigma/lean product methods to increase production while eliminating scrap and labor cost. Held status meetings with upper management and international partners concerning constraints, part status and new methods and tooling used to lower production cycle time. Streamlined production and planning processes directly with engineering in order to deliver successfully the world’s first composite commercial aircraft.

Implemented manufacturing concepts and strategies to support production objectives, installation, assembly, and tooling. Developed tooling requirements based on manufacturing and production requirements. Investigated and resolved manufacturing related issues, manufacturing processes to meet engineering requirements. Applied knowledge of manufacturing to determine the preferred installation processes.

YELVINGTON AVIATION, Daytona Beach, Fl. 5/15/06 – 5/18/07

Flight Line Mechanic (Direct)

Implemented the RVSM, Avionics and Structural Modification to both Lear 24 and 35 Series AC. Route and terminated wire bundles per. electrical installation manuals and approved engineering data. Installed system wiring, equipment, doublers and interior required for modification completion. Tested and repaired systems in preparation for first flight.

Performed aircraft inspections in accordance with Manufacturing Requirements and FAA standards. Inspected all aircraft hardware, components and structural materials for fatigue and damage. Repaired and replaced aircraft materials in accordance with approved engineering documentation.

PATS AIRCRAFT, Georgetown, De. 11/21/05 – 5/12/06

Structures Mechanic (Contractor-JSG)

Modified Boeing Business Jets both 737-700’s and 737-800’s for large structural assemblies and long-range fuel conversion mod’s. Drilled, reamed and installed structural components to close tolerance specifications. Modified stringers, ribs, and floor beams to uphold the weight exerted on the existing structure. Fabricated doublers, angles and clips for installation to framework and heavy structure assemblies. Fabricated large Gil Liner panels to close off underlying structures once structural modifications were completed, and Fuel Tanks were installed. Assisted avionics technicians where structural modifications to circuit breaker panels and instrument panels were required.

NORTHROP GRUMMAN, St. Augustine, Fl. 4/25/05 – 11/18/05

Aircraft Mechanic (Contractor-Comforce)

Performed structural modifications and repairs to EA6-B and E-2C Hawkeyes. Initiated complete tear downs of aircraft structures for inspection and repair of structural materials. Repaired damaged and corroded structure per. engineering disposition and quality MRB requirements. Assembled aircraft structure and components in preparation for first flight and customer delivery.

RAYTHEON AIRCRAFT SERVICES, Tampa, Fl. 5/24/04 – 4/22/05

Structures Mechanic (Contractor-Aerotek)

Structural support encompassing the RVSM/Avionics installation requirements for; Hawker, Premier, Beech Jet, King Air and 1900D model aircraft. Modified aircraft structure to incorporate LRU’s and corresponding antennas. Modified structural interface with avionics racks and attaching equipment per STC and DER requirements. Fabricated wiring tables/peg boards in order to fabricate and install wire bundles per aircraft modification requirements. Installed and terminated wire bundles IAW Raytheon Aircraft processes and procedures.

RAYTHEON AIRCRAFT COMPANY, Wichita, Ks. 7/21/97 – 3/15/02

Final Line Assembly

Duties include final assembly of the King Air in preparation for first flight. Fabricated metal close out panels, aircraft systems installation, fuel system installation/test, pneumatics/hydraulics/actuator installation, hung/rigged and installed engines/prop’s, operated and tested all systems required before leaving final assembly plant. Built up; center wing spar, wing stub and nacelle, nose and tail sections and worked in mating area piecing together all sub assemblies using; 10 ton over head crane, tooling fixtures, hand tools and precision measuring equipment. Initiated electrical ring-out, Systems Operations, Software Upload and Finalization, Pneumatics and Hydraulics Test. Installed and rigged landing gear, aircraft controls including; actuators, cables and surfaces.

MAXIMA PRECISION INC, Wichita, Ks. 7/15/96 – 7/18/97

CNC Operator/Set Up Technician

Operated as a set up technician, training all new hires in shop operations and customer requirements. Proficient with Cincinnati and Fadal PC based CNC Lathes and 3 axes Mills. Built up tooling and loaded CNC programs in order to run and test first part in preparation for large cycle part fabrication. Altered and added to program sequence in order to operate machines quickly and safely while minimizing scrap. Set up ISO 9000 Certification per customer requirements and engineering certification. Determines from drawings the most efficient and expedient method of fabricating parts and assemblies related to the required rate of production.

EDUCATION HISTORY

Degree from St. Petersburg College of Clearwater, Fl.

REFERANCES AVAILABLE UPON REQUEST

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