Manufacturing engineer
Resume:
Thomas A. Crisostomo
Active DoD Security Clearance (Secret),
Enrolled in Continuous Evaluation on Jan 14, 2021
Last investigation completed on Sept 20, 2018
SUMMARY and EXPERIENCE: Extensive professional experience in all phases of tooling and aircraft build applications in manufacturing engineering, and planning for commercial and military aerospace programs. Committed to Program Management and Supply Chain Management. Operations Development
(planning/scheduling) for product assembly and DFMA requirements. Including machined/fabrication parts, structural assembly and systems integration. Direct management of production operations with cost, Root Cause & Corrective Action processes.
2020-2026 Northrop Grumman-Palmdale, CA- Sr. Principal Manufacturing Engineer
• Operations & Liaison Planning Enhancement for F-35 Program
• Integrated CATIA into MS Project planning to develop and optimize procedures for tool fabrication, assembly structure definition, composites tooling, and layup processes specific to the F-35 program.
• Mapped manufacturing and assembly procedures within CATIA V5, linking 3D model-based definitions to MS Project schedules to ensure seamless communication and handoffs between design and production teams.
• Employed critical path methods (CPM) in planning to deliver clear, actionable paths for factory personnel and program management, using SAP for schedule progress tracking, resource allocation, and material requirements planning.
• Developed and documented manufacturing processes in compliance with Earned Value Management
(EVM) guidelines, facilitating robust process definitions and cost/schedule integration with live MS Schedule updates and methods integration.
• Provided ongoing technical recommendations and consultations for troubleshooting complex fabrication or assembly challenges, leveraging CATIA data for root cause analysis, rapid feedback, and process improvement.
• Collaborated cross-functionally to ensure that process changes, MS Schedule updates, and CATIA revisions were properly integrated and communicated, enabling a responsive and agile production environment.
2019-2020 GKN Corp Corporation-St Louis, MO/Garden Grove, CA- Manufacturing Engineer/Planner - under contract
• Developed tooling setup and composite lay-up processes to optimize production efficiency and quality.
• Implemented engineering and manufacturing changes for sheet metal and graphite tooling, including detailed lay-up requirement instructions.
• Planned and coordinated the manufacturing of composite structures for the F-35 aircraft, ensuring full compliance with MIL-SPEC standards.
• Utilized advanced materials and manufacturing methods, including graphite, RTM (Resin Transfer Molding), polymers, and various composite technologies/structures.
• Applied critical path analysis and network scheduling to manage production timelines and meet program deadlines.
1/2019- 6/2019 Northrop-Grumman Flight Systems Div.-Clearfield, Utah- Sr. Composites Manufacturing Engineer
• Scheduling & Planning – Aerospace Composites Manufacturing
• Managed all phases of scheduling and planning for the production of airworthy composite fabrications and assemblies in the aircraft manufacturing industry.
• Applied Earned Value Management System (EVMS) to hands-on manufacturing of composite parts, liquid jet propulsion systems, and Material Process Management (MPM) workflows, supporting both production and Research & Development (R&D) initiatives.
• Utilized Solumina and SAP to create and manage operations plans, factory capacity planning, and production instructions.
• Applied CATIA for 3D modeling, structural analysis, manufacturability assessments, and layout optimization.
• Conducted structural forecasting and provided MRO (Maintenance, Repair & Overhaul) support in collaboration with suppliers.
• Implemented lean manufacturing strategies to improve product flow, reduce waste, enhance inventory control, and strengthen customer and vendor relationships. 3/2017-1/2019 General Atomics (ASI & EMS)-San Diego, CA- Sr Manufacturing Engineer
• Lead Engineer – Project ME (Systems & Structures for Unmanned Aircraft)
• Led engineering efforts for unmanned aircraft systems and structures, including Design Build Fly projects, by planning sequences of operations and specifying fabrication procedures for tools, assemblies, forming tooling, and composite layups in accordance with aircraft design specifications.
• Utilized CATIA V for design work and managed Manufacturing Work Instructions (MWI) planning requirements daily, ensuring compliance with GD&T standards.
• Developed manufacturing processes aligned with SPC (Statistical Process Control) guidelines, defining and implementing improved procedures for rework and for production of sheet metal and composite components.
• Provided technical recommendations and consultative support to resolve production and assembly issues through direct factory floor troubleshooting.
8/2015-3/2017 Northrop-Grumman, Palmdale CA- Sr Manufacturing Engineer
• MRB disposition and project management for aircraft installation manufacturing.
• Planning and engineering design for F35 military aircraft, metal bond and tool detail components, for both EMD and LRIP requirements.
• Supply chain management/MRO and accommodating tool vendor requirements, and technical input for tooling and assembly processes.
• Supply chain management and accommodating tool vendor requirements, and technical input for tooling and assembly processes.
• Planning operations and tooling for flight control areas (flaps, ailerons, elevators, rudder control column and installation rigging.
• Responsible for manufacture of aircraft and structural parts/assemblies.
• Approval of fabrication of machined parts, interiors, etc.
• Provided liaison as required with Manufacturing & Design Engineering and MRB for avionics systems/flight controls for brakes and landing gear installation. 1/2014 – 8/2015 Honda Jet, -Greensboro, NC- Sr Manufacturing Engineer - under contract
• Planning operations and tooling for flight control areas (flaps, ailerons, elevators, rudder control column and installation rigging).
• Responsible for manufacture of aircraft and structural parts/assemblies (HondaJet supplier approved fabrication of machined parts, interiors, etc.) for first time build and research and development.
• Provided liaison as required with Manufacturing & Design Engineering and MRB for avionics systems/flight controls for brakes and landing gear installation.
• Liaison lead in navigation and flight controls.
• Instruction to key personnel to devise new approaches in resolving unusual or complex engineering and delivery challenges.
10/2010 – 12/2013 General Atomics Corp. – San Diego, CA – Sr Program Manager
• Project management lead for UAV production program for electromagnetic and avionics systems.
• Team liaison with 5 members for systems design engineering in production and manufacturing with Integrated Master Plans (IMP) and program execution with SOW.
• Liaison lead in satellite navigation and flight controls.
• Instruction to key personnel to devise new approaches in resolving unusual or complex engineering and delivery challenges.
• Liaison for Germany/Deutschland operations with Rolls Royce engineering, supplier support and production processes.
6/2008 – 10/2010 Northrop-Grumman Corp. – San Diego, CA – Change Operations Manager–
• Create and maintain change/configuration operations activities for engineering and production lector- mechanical actuators for Global Hawk aircraft.
• Responsibilities include operational entities and providing process metrics and Engineering Changes and ERP to IPT’s.
• Executed SAP requirements for operations to include Bill of Material within our Design and Engineering team.
• Maintenance of MS Project schedules, ECN’s, change requests, Teamcenter Configuration Management.
• Create and track to spreadsheets involving tracking for all depts. reporting daily status to Change Operations, including CCB, TRB and final with Document Control/Release.
• Scheduling and planning in the aircraft manufacturing industry; projects included in the Global Hawk and UAV aircraft actuators, steels (non-exotic & exotic).
• Applied design methodologies, updates and product development efforts for airworthiness.
• Created Block Scheduling with use of MS Project for composite parts, assembly and bonding.
• Utilized Material Process Management processes for chem-treat, paint and NDT, etc. 7/2007 – 6/2008 Northrop-Grumman - San Diego, CA - Program Manufacturing Manager-
• Scheduling and planning in the aircraft manufacturing industry; projects included in the Global Hawk, UAV GPS methods.
• Applied design methodologies, updates and re-design efforts for airworthiness.
• Led first time build product development projects in the aircraft manufacturing, including the Global Hawk and UAV GPS system methods.
• Created Block Scheduling with use of MS Project for composite parts, assembly and bonding.
• Utilized Material Process Management processes for chem-treat, paint and NDT, etc.
• Lean manufacturing and establishing methods of corrective action and use of CAPP and BOM.
• Managed operations (scheduling/planning) with SAP.
• Provided Vendor engineering support and procurement manufacturability. 1/2007 –6/2007 Eaton Corp.- Ft. Worth, TX- Sr. Project Engineer - under contract
• Manufacturing engineering and mechanical design for JSF actuators, hydraulics components and electro- mechanical flight control systems.
• Initiate MRB corrective action and stress analyses for engineering design changes per customer requirements, per MIL STDS including Engineering review documents for deliverability and FAI standards.
• Planning and scheduling for manufacturing development and assembly, with use of Failure Mode and Effect Analysis (FMEA). CATIA V5 and V6 experience. 6/2003-3/2006 Northrop-Grumman Military Aircraft Div.-El Segundo, CA- Program Planning - under contract
• Addressed all phases of scheduling and planning in the aircraft manufacturing industry; projects included FA-18 E/F/G aircraft.
• Applied Earned Value Management System (EVMS), WBS Scheduling on MS Project; utilized Material Process Management (MPM) and Microsoft Project experience.
• Handled facilities operations & planning for aerospace capacity, layout usage concepts.
• Structures analysis and forecasting. MRO experience with suppliers.
• Applied lean manufacturing strategies to manage customer support, vendor liaison, product flow and inventory.
2000-2003 Hydro-Aire Aerospace, Burbank, CA- Sr. Program Manager
• Program/Manufacturing planning in a cross-functional team environment; supported commercial production in a critical path/development systems environment with use of FAA guidelines.
• Integrated cost schedule management activity for new/existing projects.
• Provided liaison as required with Manufacturing, tooling; addressed sustainability assessment efforts, repair/overhaul dispositions and planning; maintained CDRLs.
• Earned Value Concepts
• Incorporated Engineering/Manufacturing changes for ground systems/ test equipment (MS Project; BOM). PM for 737, 757, 767, 747 models, including freighters.
• Initiated MRB corrective action and stress analyses for engineering design changes per customer requirements, per MIL STDS including Engineering review documents for deliverability and FAI standards.
• Planning and scheduling for manufacturing development and assembly, with use of Failure Mode and Effect Analysis
(FMEA).
1997-2000 Northrop-Grumman Military Aircraft Div.-Hawthorne/El Segundo, CA- Sr. Mfg. Eng. - under contract
• Planner/Manufacturing Engineer (operations/composites); handled tooling set-up and lay-up processes.
• Incorporated Engineering/Manufacturing changes for sheet metal and graphite tooling with layup requirement instruction.
• Planned the manufacture of composite structures for the FA-18 E/F Aircraft (with required Mil- Specs usage) including usage of graphite, RTM/Polymers and composites mfg. technologies/structures.
• Use of critical path analysis and network schedules.
• Manufacturing Engineer responsibilities for 747 included planning operations and tooling. Incorporated Engineering and Manufacturing changes for Boeing 747 & F-18 composites/related tooling.
• Provided engineering liaison as required with Design Engineering, Manufacturing, Tooling, QA and ground systems.
1995-1997 McDonnell-Douglas (Boeing) Corp.-Long Beach, CA- Manufacturing Engineering Manager
• Manufacturing Engineering manager for assembly tool design group of 18 employees.
• Responsibilities included operations and tool planning for Nose/Radome Forward Fuselage & Join for the MD-95 Aircraft.
• Performed in a liaison capacity with Design Engineering, Tool Design, first time build for the 777, research, development, QA and budget/cost forecasting and manpower requirements.
• Incorporated Six Sigma into the critical path/development analysis effort.
• Planned operations and tooling for assembly and test of the C-17 aircraft using Boeing commercial structures and fasteners.
EDUCATION
UCLA – From 6/82 – 6/86, Mechanical Engineering,
Courses included: Aerospace Engineering, CADAM/NCAD, Mechanics, etc. UCLA – From 6/86 – 6/91
U.S. and International Business Study--Courses included: Business Law, Principles, Economics, Business Administration, etc.
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