Aircraft Platforms
I worked on multiple helicopter configurations, each with unique structural and avionics requirements across various mission profiles.
AW119 Helicopter
Single-engine light utility helicopter
- Educational vehicle and flight training
- Medevac and emergency services, search and rescue (SAR)
- Obsolescence and configuration updates for legacy systems
AW139 Helicopter
Medium-sized twin-engine helicopter
- Luxury transport and VIP travel
- Light-combat zone operations
- Lean manufacturing of mature product line
Key Projects
Process Control and Quality Preparation
Prepare detailed structural models, assembly layouts, and quality control documentation to support project development and manufacturing operations.
- Generated detailed part and assembly drawings
- Created bills of materials and work packages
- Implemented Key Inspection Points (KIPs)
- Ensured compliance with customer and governmental required specifications
- Rectified nonconformities and recurring defects through Manufacturing Inspection Reports (MIRs) and root-cause analysis (PFMEAProcess Failure Mode Effects Analysis and 5-Whys)
- Managed a JIRAIssue-tracking and Workflow Management Tool-based feedback system where technicians and mechanics submitted process issues, implementing engineering solutions and corrective actions
Structural Integration and Engineering
Led integration and installation design for avionics and structural equipment on contoured airframe surfaces and cabins. Oversaw CADComputer-Aided Design validation, fit-up, and production readiness for complex assemblies, ensuring manufacturability and regulatory conformity.
- Directed integration for curved tailboom and cabin surface installations
- Developed installation layouts for VORVery High Frequency Omnidirectional Range, VHFVery High Frequency, and navigation antennas
- Improved design-to-production workflow through iterative CAD model validation
Tools Used:
DIT-MCO 2115 Testing Unit Implementation
Led capital purchase and implementation of advanced testing equipment to verify proper mechanical installation of avionics systems, dramatically reducing verification time. The unit replaced manual pin-to-pin verification, improving traceability and reducing inspection cycle times.
- Managed Capital Expenditures purchase process and justification
- Coordinated equipment integration into production flow
- Developed testing procedures and protocols
- Trained technicians on equipment operation
- Streamlined avionics verification workflow
ISO 9001 / AS9100 Cost Optimization Tool
Developed a department-wide VBA tool used by engineering staff including Chief Production Engineers to automate cost analysis and track savings from design improvements.
- Automated correlation of design changes to cost metrics and tracked labor savings across multiple projects
- Built and maintained an ISO 9001International Standards Organization / AS9100Aerospace Standards-compliant work instruction database with standardized templates
- Generated reports for upper management presentations
- Deployed across entire manufacturing engineering department in USA
Sheet Metal Sealant Standard Operating Procedure
Developed and introduced a comprehensive Standard Operating Procedure for sheet metal sealant application, optimizing both efficiency and environmental protection.
- Standardized sealant application techniques
- Enhanced environmental sealing effectiveness
- Reduced rework and quality issues
- Improved technician training materials