Engineer Quality Assurance

**-**** ***** ** ******** hands-on contributions to advance product development and value engineering

projects, within both military and commercial sectors, earning industry respect and a functional edge into design and

produciblity. Strong communicator, self starter, and self motivated. Strong in analytical analysis of data, ability to see value & waste; Broad picture perspective with a drive for closure.

- Effective hands-on Lean Six-Sigma Manufacturing experience- GB certified / BB trained

- Practitioner of Lean and process simulation (30 years)

- Effective liaison between production, engineering and quality.

- Demonstrated strengths in the analysis, development and implementation of improved value stream methodology in

refining processes, realizing a $68M savings in direct costs.

- An astute, team player and motivator who adapts to varying situations.

- Adept in technically-savvy teams with an ability to communicate with all stakeholder levels, from shop floor to senior

management, customers, and suppliers.

- Continued completion of projects that are under budget and ahead of schedule.

- Developed and managed product cost reduction projects resulting in 85% savings.

- Successful coordination, design and planning of a $50M CAPP and production system.

Manufacturing Engineering and Process Improvement:

Lean- Six-Sigma, Tool Design & Liaison, M.E. MRB authority, Strong Demand Flow Technology, Pull Manufacturing and

Cycle Time Reduction experience, Chaku Chaku, Poka-yoke, commercial / aerospace methodologies. NPI and

sustaining/?Moonshine? support- E/M and Black Box, PWB?s, CCA?s: PTH, SMT, and MCM. Wire Harness & Cable

(Fab/Assy), Product and Process Costing, Time Studies PRB / MRB; FMEA, FRACAS, ICA

Quality Assurance:

ISO Implementation and Transition: ISO 9000/1994 to 9000/2000; Supplier Qualification; Suppliers Quality Support &

Engineering; PRB / MRB; Workmanship: Printed Circuit Assembly, Assembly and Machine Shop Environments; SPC;

Inspection; FRACAS; Technical Writing: Process and Work Instructions, Training Guides, Lesson Plans and Courseware,

CMMI, ICA, Six-Sigma.

Tools Communications & Software:

Business Data Graphics & Web Engineering

MS Office 2003/7/10 Oracle / Brio | PDM | SQL Adobe CS3 Suite ACAD 2009 / Inventor

MS Project2003/7/10 MS Access / MS Excel vBulletin CATIA V5 / Delmia

SAP ERP / CRM Minitab / SPSS

VBA / SQL / MySQL Flash | Freehand

JAVA / PHP / CSS iGrafx Six Sigma 2007

FlexSim

Professional Affiliations & Interests (current & former):

ASQ, PMI, IPC, SPE, ASME, SME, IEEE, SAE, MIL-STD 2000 HDBK. Cmte., ISO 9001:1994/2000, AMA, Toastmasters Intl,

World Affairs Council, Citizen Ambassador Pgm., LMLA, LMCO Full Spectrum Leadership.

Qualifications:

US Citizen; Secret clearance [Inactive], Top Secret (USN) [Inactive]; FDA/GMP, ISO

History:

03/5/2010- 9/29/2010 Hawker Beechcraft Little Rock, AR

Lean Operations Engineer, Sr. Manufacturing Lean Activities / SCM Continuous Improvement - Contract

Supported efforts across functional teams in collaboration and integrated logistical support of lean initiatives. Assignment

comprised two distinct facets: 1) Support of Supply Chain Management projects to reduce logistical and inventory costs

by identifying and correcting Supply Chain and Logistics problem areas; 2) The preplan and development of a lean vision

in support of new operational lean initiatives. The goal was the transformation of existing, supply chains and production

operations, to achieve material flow and integration of multi-tiered value streams in improving production throughput and

operational cycle time at lower cost. Integral was supplier, both internal and external, operations and manufacturing

techniques maximize quality yield and minimize non value added processes/steps.

- Leveraged training in LM21 techniques and tools in driving lean initiatives.

- Developed and presented site-wide Lean refresher training program.

- Catalyze the importance Value Stream Mapping (VSM) beyond simple flows.

- Lead breakthrough initiatives within Paint Shop in forming a new cultural awareness towards excellence in a

post-RIF environment.

- Drove changes in Paint Shop IPT in maintaining balanced material consumption, reduced material and process

waste and forged a cultural change of pride of ownership by shop personnel.

- Laid groundwork for new tool control system.

- Identified positioning of inventory strategically in the extended value stream to reduce lead times and minimize

the need for finished goods safety stock in Woodshop, Sheetmetal and Paint.

- Leveraged information flows to synchronize all tiers of the value stream and reduce the risk of supply chain

disruption.

- Identified opportunities and proposed solutions to reduce or eliminate environmental impacts such as the

proposal of replacing MEK with MPK and other environmental friendlier solvents in paint processes.

09/15/2009- 11/25/2009 Lockheed Martin Aeronautics Marietta, GA

Manufacturing Engineer, Sr. Corrective Action / Continuous Improvement- P3 Wing- Contract

Supported Tank Seal, Wing Lay-down and Paint IPT?s in maintaining Build to Package (BTP) elements; such as, corrective

action (CA), datasets, models, tool design, tool manufacturing work Instructions, Applications List/Parts List/List of

Material (AL/PL/LOM), change proposals, manufacturing bill of materials (MBOM) change request, specifications, work

instructions - detail/assembly/installation and, process improvement and produciblity.

- Trouble-shot production issues. Assisted Reliability Engineering and Quality Engineering with Corrective Action

and Workmanship Issues (ICA).

- Reviewed tooling designs and recommended design tooling, closed tooling/production issues by streamlining

processes and interpreting tool design.

- Reviewed and submitted corrections to tooling and airframe drawings.

- Guided tank seal and lay down SWBS towards redesign to accommodate 2010 production ramp-up.

- Worked closely with planners on detail work instructions.

07/1/2009- 9/28/2009 Northrop Grumman Ship Building Avalon, LA

Quality Assurance Analyst , Corrective Action - LDP USS New York - Consultant

Interim assignment to support production of LPD-21: corrective action (CA), and Quality database administration and

maintenance.

03/4/2009- 4/28/2009 Wulfsburg Electronics (Cobham) Prescott, AZ

Corrective Action - Consultant

Brief assignment to help identify opportunities to increase first pass yield of older legacy product line.

12/5/2008- 12/15/2008 ITT-EDO Manassas, VA (Salt Lake, UT)

Manufacturing Engineer, Sr. / Pre-production Build- Consultant - Consultant

Brief assignment to support a supplier pre-production delivery of an advanced SONAR processor for US Navy.

1/2008-8/22/2008. Lead Lean Process Engineer: Honeywell Defense Systems, Albuquerque, NM Avionics: Production

and Repair and Overhaul

Contractor: Interfaced with and supported customers, Program Management, Engineering and ISC, as a whole, in

continuous improvement activities for manufacturing process and industrial engineering efforts; Designed, managed

implementation of site-wide mix-model Aftermarket Repair and Overhaul production line. (F18, F16, F2, T45, T50, C130,

B707, RNZAF, OH58, MAV, CH47, C5)

Coordinated with community, supporting various programs and sites to establish optimum/"best fit" processes and

procedures. Lead efforts to deliver, and support, tactical as-well-as strategic, continuous improvement processes.

Supported mix-volume production Work Centers in a Demand Flow environment; Work Center support consisted

maintaining and improvement of controlled-environment and non-clean room manufacturing, as well as kaizen

participation;

Acted as liaison between shop floor and Engineering sustaining solder, electro-mechanical mechanical assembly, wire

harness and cable prep, conformal coating production of avionics; Supported MRB activities. Maintained tooling and

CAPP planning; Updated computer databases and engineering configuration requests for new parts development and

concurrent engineering; Wrote instructions for potting, braiding and general wire assemblies, conformal coating;

Introduced and implemented PDK?s, Kan Ban methodologies on production floor to improve overall production support;

Assisted Quality Engineering with Workmanship Standards. Project ended due to budget cuts.

04/2004-01/2008. Sr. Process Engineer: Lockheed Martin (Space Systems Division), New Orleans, LA Space Shuttle

Return to Flight (RTF), External Tank (ET)

Contractor/Direct: Contributed to several RTF teams in a variety of supporting roles during the Verification and Validation

(V&V) efforts of the Spray-on Foam (SOFI) and Pour Foam (PDL) applications. Support consisted of interpreting customer

requirements and coordinating mechanical production and CERT mockup design and fabrication, cost, schedule and

facility processing. This involved the design of the fabricated mechanical substrates, assembly and foamed end item.

Coordinated Manufacturing Process (PPD) & Process Plans (MPP); wrote Assembly and Process MPP?s in HMS CAPP.

Actively participated with Production, Quality and Design Engineering (Systems & Structural) and Safety, as-well-as other

Process & Manufacturing Engineering team members, in developing engineering requirements for ET Longeron, PAL

Ramp, Bellows Heater, and Volume Fill; Worked closely with Production, Tool Engineering, Tool Fab, Industrial and

Facilities Engineering. Reviewed tooling designs and recommended design tooling; Developed facility requirements,

supporting mockups and tooling. Answered NCD?s and reviewed drawing redlines changes for MRB; Participated in

Kaizen efforts, cause and corrective action and Pre-board support. (SAP-ERP, RTM?s, PPD?s, MPP?s, SDS, RFF, NCD, MS

Project, MS Excel, HMS CAPP, Autocad Mechanical desktop, CATIA V5)

03/2003-3/2004. Sr. Manufacturing Engineer: Lockheed Martin (Aeronautics Division) Fort Worth, TX Mate-Through-

Delivery (MTD), F-16 Aircraft Production

Contractor: Supported a broad range of shop needs in areas of process improvement, cost reduction and schedule;

Acted as liaison between Production, Quality and Design Engineering (Systems & Structural). Reviewed tooling designs

and recommended design tooling, closed tooling and production issues by streamlining processes and interpreting tool

design. Interfaced with CAPP Planners and oversaw line sequencing and produciblilty issues. Reviewed drawing redlines

changes for CRB; Updated computer databases and engineering configuration requests for new development and

concurrent engineering; Trouble-shot wire harness and cable production issues; Assisted Reliability Engineering and

Quality Engineering with Corrective Action and Workmanship Issues.

(IMS, QADS, EDMS, Formtek, ADAP, REA. CAPP?s, GD&T, CATIA V4)

08/2001-01/2002. Quality Assurance Manager: EIM Controls, Missouri City, TX

Valve Actuator Manufacturing.

Contract: Managed and maintained the Quality System in accordance with Federal and ISO requirements; Performed

internal audits of manufacturing and supplier sites. Represented EIM to ISO 9001 authorized body. Interfaced with Factory

Mutual (FM) and ISO Auditors; Worked closely with Manufacturing and Purchasing; Supervised activities of personnel in

Inspection and Engineering Research Lab. Acted as primary focal for Discrepant Material Review and Non Conformances

(DMR/NC); Conducted manufacturing engineering evaluations. Directed the development of an online document control

system for QA and QA database (Lotus Domino-based & non-Lotus, Web Intranet); Developed an on-line training course

with database links for QA Department along with training material.

01/2000-02/2001. Sr. Manufacturing Engineer: Applied Materials, Austin, TX Semiconductor Fabrication Tool

Manufacturing.

Contractor: Support of mix-volume production Work Centers in a Demand Flow environment. Work Center support

consisted maintaining and improvement of clean room and non-clean room manufacturing, as well as kaizen

participation. This included resolving product and process issues, creating and maintaining manufacturing

documentation, methods sheets, line design and balancing, including Lean Manufacturing improvements and cycle time

reduction; Responsible for ECO implementation and design maintenance of product line. Duties included product design

changes and review; Supported efforts on the redesign and realignment of production lines and the clean up, along with

maintenance, of the production Manufacturing Assembly Parts List (MAPL); Directed the creation and maintenance of

illustrated work instructions (methods sheets); Acted as primary ME Focal for Discrepant Material Review and Non

Conformances (DMR/NC) for specific product line and back-up ME Focal for Suppliers Issues (SPS) across all products at

location for Modules Engineering through FRACAS. Enjoyed close working relationships with the Work Center, Logistics,

suppliers, Supplier Quality Engineering (SQE) and Quality Engineering (QA) resolving engineering and safety issues.

8/98-5/99. Sr. Manufacturing Engineer: Raytheon Missile Systems, Tucson, AZ E/M, Wire Harnesses and

Flex Cables, and Composites.

Contractor: Liaison between shop floor and Engineering - transitioning and implementing various pre-production and

production levels for a variety of missile products; Updated computer databases and engineering configuration requests

for new parts development and concurrent engineering. Developed tooling and work instructions for E/M assembly,

tooling, wire wrap, potting, general wire assemblies, painting and bonding procedures: Utilized Polka Yoke methodologies

on production floor to improve overall production support; Assisted Quality Engineering with Workmanship Standards

and PDM indoctrination and training of peers. In addition to regular duties, lent support to local area network:

troubleshooting user software and hardware problems, training and liaison between users and primary IS support.

12/91-8/98. Technical and TQC Support to Engineering: Synthegraph Industrial Resource Group, San Diego, CA -

Oshkosh, WI, Farmington, NM

Consultant: Provided technical support to electro-mechanical and mechanical production lines and quality assurance;

synthesized engineering and marketing documentation to produce manufacturing processes and procedures. Wrote

procedures for operation and tooling instructions, inspection methods and interfaced with principal representatives from:

Marketing, Engineering, Quality, Manufacturing Engineering and Production Control to maintain production schedules;

Included the development and production of user operating instructions and reference material. Additional support

included: Intranet/Internet design and implementation, financial and business plans, migrations and training; Six Sigma

consulting to Services Industry.

07/89-11/91. Project Engineer: New/Transition Product Development and Implementation.

Sundstrand Power Systems (A Div. Sundstrand Aerospace), San Diego, CA

Consultant: Lead a transition team of seven in the cost and producibilty analysis leading to the cost reduction of an

avionics black box system for use on the Boeing 757 and 767 aircraft under the auspices of ARINC and ISO 9002. This

involved the E/M packaging associated with SMT, ASIC?s, and multi-layer PWB?s, cabling and the chassis assembly itself.

Trouble-shot manufacturing production problems, conferred and exchanged data with vendors, integrated quality

assurance plans with manufacturing and engineering automation assets; Maintained BOM?s and engineering notebooks.

Developed manufacturing criteria and tooling for SMT, PTH and MCM - based CCA assemblies. Developed computer

aided design and modeling tools for future builds; Pioneered the development and production of SPS?s first successful

conductive injection molded black box chassis and rack mount system, currently in use on the Fokker and SAAB 2000

Aircraft; Introduced Taguchi and Kan Ban methodologies; Implemented M.E. CAD/CAM Concurrent Engineering and

workstation capabilities.

09/88-6/89. Sr. Manufacturing Engineer: Wire Harnesses and Cables.

Sikorsky Aircraft, (A Div. of United Technologies) Stratford, CT

Contractor: Acted as liaison between shop floor and Engineering sustaining wire harness and cable production for Black

Hawk and Sea Hawk aircraft as well as the CH-53 series aircraft; Maintained harness tooling and CAPP planning; Updated

computer databases and engineering configuration requests for new parts development and concurrent engineering;

Wrote instructions for potting, braiding and general wire assemblies; Introduced and implemented Kan Ban & Polka-Yoke

methodologies on production floor to improve overall production support; Assisted Quality Engineering with

Workmanship Standards.

08/87-09/88 (...8/89). Project Engineer: Manufacturing and Design-Integration and Automation (aka, Lean Six Sigma)

McDonnell Douglas Strategic Defense & Electronics Company, Huntington Beach, CA

Consultant: Lead a team of nine, which facilitated operational and technical automation of the wire harness, black box,

CCA technology working groups (Cells) for the Delta rocket factory. This effort impacted 10 SBU?s. Evaluated the

manufacturing capabilities of, and support for, the electrical and electronic production teams, recommending corrective

action and realigning trends for production support, while concurrently supervising design and implementation of a CIM

network for a JIT facility. Planned, designed and supervised cost studies of the [then] current and future needs for

software development and computer networks consisting of a WAN, comprised of LAN?s incorporating: VAX/VMS, DOS-

based PC?s, Macintosh and Unix work stations, which integrated the resources of all production support and engineering

services; Included the capture of expert manufacturing engineering and planning data and experience, and instituting

retraining programs.

11/86-10/87. Project Engineer: Manufacturing Workmanship/Processes: PWB?s & CCA?s.

Hamilton Standard (A Div. of United Technologies), Windsor Locks, CT

Contractor: Electronics Manufacturing Engineering team lead for an SSR/CORE Team for Workmanship and Cause and

Corrective Action for PWA and CCA production for use on the F-18 aircraft. Developed and published an illustrated

Workmanship Standard for PWA?s and CCA?s for SMT and Thru-hole assemblies, hand and wave solder and mechanical

assembly; Supported Quality Assurance and Mechanical assembly.

12/85-9/86.Manufacturing & Engineering and Technical Support

Synthegraph Industrial Resource Group, Santa Ana, CA

Consultant: Supported electromechanical and mechanical production lines; synthesized engineering documentation to

produce manufacturing processes and procedures. Wrote procedures for operation and tooling instructions, inspection

methods and interfaced with principal representatives from: Engineering, Quality, and Manufacturing Engineering

02/79-8/79; 01/82-1/85; 8/85-11/85. Sr. Product Development Engineer E/M, Wire and Black Box

Hughes Ground Systems Group, Fullerton, CA & Hughes Microelectronics, Newport Beach, CA

Lean Manufacturing Developmental Engineer; instituted $64M in producibility changes and enhancements.

Education

2009 American Intercontinental University

BA, Business- GPA: 3.0 Buckhead, GA

2005/2006 Villanova University

Certificate: Black Belt Mfg. Six Sigma- GPA: 4.0 Villanova, PA (online)

06/2005 Villanova University

Certificate: Six Sigma Mfg.- GPA: 4.0 Villanova, PA (online)

2002 University of Phoenix

BSB/EB, Business- GPA: 3.82 (incomplete) Phoenix, AZ

2000 Applied University

Certificate: Lean Manufacturing Austin, TX

1975-1976 Defense Language Institute

Russian Language- GPA: 3.6 NAVSECGRUDET, POM, CA

Brooks Childs RESUME 2010.10.2

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5500 Higlanddr.,#1724 * Little Rock, AR 72223 * Cell Phone 505-***-**** * e-mail: ********@*****.***

Brooks S. Childs

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2010.10.2

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