Program Manager with MBA, MSc and BEng (1st class Hons) in aeronautical engineering with 17 years’experience across technical and management disciplines such as:
MANAGEMENT: PROJECT (Microsoft Certified Professional - Project 2010), ENGINEERING and OPERATIONS management, STRATEGIC PLANNING, BALANCED SCORECARDS, FINANCIAL & MANAGEMENT ACCOUNTING (MBA), SUPPLY CHAIN development, BUSINESS DEVELOPMENT and QUALITY MANAGEMENT SYSTEM design / implementation. Studying towards PROJECT MANAGEMENT PROFESSIONAL (PMP) certification by the Project Management Institute (PMI).
TECHNICAL: STRESS / STRUCTURAL ANALYSIS of METALLIC and COMPOSITE structures such as AIRCRAFT wing spars, skins/covers, trailing/leading edge, wingtip/winglet, fuselage, CONCESSIONS and SPACECRAFT using HAND CALCULATIONS, software such as ISAMI and FINITE ELEMENT ANALYSIS (PATRAN, FEMAP, SIMXPERT, and ANSYS).
• Program management of the (Confidential) payload fairings utilising a large team of design and analysis engineers from stakeholder engagement, review of statements of work (SoW), requirements capture, creation of work (WBS) and resource breakdown structures (RBS), risk and quality management plans, budgets, scheduling with Microsoft Project 2016 and creation of commercial proposals and subsequent negotiation with the customer.
• Creation of quality management system (QMS), configuration management processes/ procedures (design evolution and scope change control), implementation of monitoring and control techniques to manage quality and utilising earned value (EV) management (schedule variance, Cost variance, Estimate to Completion) to continuously monitor cost and schedule variances against baseline, manage risks, resource and initiate corrective actions if deviations occurred in order to adhere to financial, schedule and quality objectives.
Project Manager – Airbus A350-900 MSN21-39 Wing Fixed Trailing Edge (FTE) Certification
• Managed the certification of the wing inner fixed trailing edge utilising GE-Aerostructures and supply chain analysis team through creation of work and resource breakdown structures (WBS/RBS), engagement of supply chain through creation of statements of work (SoW) and
implementation of monitoring and control utilising Microsoft Project 2010 project management software and PM techniques such as risk, dependency, action registers, S – Curves and KPIs (including Earned Value Analysis) to track variances against baseline plan, manage risks, quality and initiate corrective actions if deviations occurred in order to adhere to technical and cost/schedule objectives. The Aircraft Certification Document (ACD) data was consequently delivered to Airbus according to the planned schedule and Earned Value CPI and SPI indices >1 were achieved.
Project Manager – Verification and Validation of Airbus A350 Flap Support Structure and Fairings
• Accountable for Saab’s adherence to the Airbus A350 Flap Support and Fairing Structure requirements for the complete design, stress (including particular risks such as wheel and tyre failure and bird strike), manufacturing and maintainability aspect using project management techniques such as risk, dependency, action registers, S – Curves and KPIs to track actual progress against plan, manage risks, resource and initiate corrective actions if deviations occur in order to guarantee delivery of requirements to the customer by resolving technical and schedule issues with a team of lead engineers and engaging with Saab and Airbus Germany senior management. The C-Scheme requirements were consequently achieved and approved by Airbus in line with the schedule.
Airbus A350 Centre Fuselage Delegated Stress/Structural Analysis Signatory/Approver
• Within only 3 weeks of assessment by Spirit Aerosystems I was identified for A350 centre fuselage delegated stress signatory, the norm is 6-12 months. The assessment involved reviewing stress and design assessment of deviations on metallic and composite structure such as delamination, erroneous drill starts, flaking, impact damage and others predominantly using Airbus ISAMI V 7.2 software. Due to a family bereavement I had to relocate to Europe before undertaking the signatory role.
Deputy Manager - Product Engineering Division
• Managed the product engineering support to ensure delivery schedule adherence of the AIRBUS
A380/A330 composite flap track fairings to customer (FACC - Austria) using project management tools such as risk, dependency, action registers, S – Curves and KPIs to track actual progress against plan, manage risks, supply chain, resource and initiate corrective actions if deviations occurred in order to support production planned shipment profile. Consequently, there was a departmental performance turnaround as delayed ship-sets were promptly cleared for shipment, and all new parts either cleared before, or precisely in time for shipment.
• Mentored U.A.E. stress engineers to resolve non-conformances (concessions) on composite parts such as porosity, delamination and core defects that arose during layup and assembly using Finite Element Analysis (PATRAN/SIMXPERT) and hand calculations. Appointed as the customer technical focal point and checked all engineers' work before submission to customer on AIRBUS SAP system. Engaged with the quality department to improve composite part NDT inspection methods (C-Scan and A-scan investigations) and repair procedures, resulting in the overhaul of NDT defect classification methods within the company.
Deputy Lead Stress/Structural Engineer - AIRBUS A319 Corporate Jet
• Managed 12 stress engineers and supply chain in order to deliver the stress reports for AIRBUS A319 supplementary type certificate (STC) approval and liaised with EASA airworthiness authorities as the technical focal point. All reports were delivered on time and to budget.
• Undertook hand calculations from first principles in order to size a range of composite and metallic structures. The analysis also covered the reassessment of the primary structure at interfaces such as frames, stringers, seat tracks, intercostals, cabin/cargo bay floor structure and concessions. Subsequently, within weeks of joining the project I was given stress signature authority for the complete aircraft and appeared in company newsletter.
Deputy Lead Stress/Structural Engineer - AIRBUS A350 Fuselage Cargo Door Surround
• Sized the cargo door surround composite and metallic support structure using hand calculations and Airbus stressing tool ISAMI V6 to assess bolted joints, open holes (cut-outs), panel buckling, plain strength etc. I combined all local FEMs into a design FEM (DFEM) to bring the model up to B-Scheme standard so it could be incorporated into the Airbus GFEM (using PATRAN V. 2010 and NASTRAN). Due to extensive experience with Airbus tools guided other stress engineers within theteam on the correct use and applicability of the ISAMI stressing tool in addition to general Airbus analysis methods.
Stress/Structural Engineer – IXV Spacecraft
• Sized multiple composite and metallic structural components using classical hand calculations and FEA (PATRAN V. 2008/2010) for the achievement of customer C-scheme approval of the Intermediate Experimental Vehicle (IXV). Adopted and developed MathCad methods for composite sandwich panel and insert analysis and also established new metallic calculation tools to reduce analysis cycle times.
Stress/Structural Engineer – AIRBUS A350 Winglet/Wingtip (Luzern)
• Sized composite and metallic structural components of the A350 composite wingtip to winglet joint for achievement of B-scheme sign-off by AIRBUS UK using classical hand calculations (Airbus metallic and composite methods) and FEA (PATRAN V. 2008). Advised design team throughout sizing iterations to achieve optimum structure.
Lead Stress/Structural Engineer – Airbus A400M Composite Wing Skins
• Led the composite wing generic skins and leading/trailing edge interface analysis for the MSN 1 First Flight Clearance (FFC) to assess the structure against an expansion in the existing load envelope. Reassessed existing reserve factors (RFs) due to the change in loading and updated all analyses (e.g. skin/stringer strains, stability, rib to skin bolting, stringer termination bolting and fuel passage holes etc.). All low RFs were subsequently resolved and reports delivered on schedule to the customer.
Project Manager– AIRBUS A380 Fuselage
• Established the company’s first project with Airbus Germany, setting up infrastructure, extended enterprise, QMS procedures and recruitment of design team to update A380 fuselage drawings with DQNs/Mods using CATIA V.5 software. This consequently resulted in KPI performance exceeding the work package (WPRS) requirements and being offered a position at Airbus Germany.
Project Manager - A400M Composite Wing Skins
• Managed the Airbus composite wing panel drawing and stress design file delivery schedule with a team of 32 design and stress engineers. Project Management methods such as risk, dependency, action registers, S - Curves and Gantt Charts were used to track actual progress against plan, manage risks, supply chain, resource and initiate corrective actions if deviations occurred. Performance resulted in receiving customer’s (Airbus UK) praise at high-level management reviews for quality, delivery schedule adherence and risk management.
• Requested by the CEO to support him with business development in order to grow organically and also acquire new customers globally. Developed and gave company sales presentations in Europe and U.S., resulting in the enhancement of the company's customer portfolio.
• Sized the MSN 6 Entry into Service (EIS) composite wing skins at the leading and trailing edge interfaces using Airbus ESAC analysis tools such as the bolted joint method (bearing bypass), bolt/composite failure, buckling, open holes, build stress and concessions analysis. Developed further tools and methods to reduce analysis cycle time and achieve skin weight target. These tools and methods subsequently became the baseline for the first flight clearance (FFC) analysis undertaken by an Airbus Deutschland supplier.
1998 – July 2006
Engineering Operations Manager
• Developed a Business Strategy for the AIRBUS UK manufacturing support business to achieve company growth targets. Credible strategy resulted in a request from the board of directors to develop all future business strategies.
• Initiated and implemented the expansion of low cost Strategic Supply Chain (INFOSYS and HINDUSTAN AERONAUTICS) across all business divisions to support growth of AIRBUS UK and AGUSTA/WESTLAND HELICOPTERS, leading to 50% average cost benefit.
• Managed a 120% company growth in turnover within 12 months from £4.5M to £10M to support customer demand, resulting in unprecedented company profitability with minimal disruption to delivery schedule during initial learning curve phase.
• Led programme reviews and problem solving sessions for business unit managers to meet challenging and dynamic business requirements to support company growth targets and also developed and implemented a Quality Management System resulting in AS9100 approval.
• Initiated customer relationships and managed requirements at both senior and operational levels to develop customer specific strategies. Gave sales presentations to generate organic growth with existing customers and also enhance customer portfolio, resulting in record growth of 120%.
Engineering Manager – AIRBUS UK manufacturing support business
• Grew the Airbus UK manufacturing support business unit resource level from 17 to 52 within 9 months to support customer’s additional aircraft orders, resulting in record increase in turnover of 250%.
• Developed a low cost Strategic Supply Chain with INFOSYS to support AIRBUS UK growth resulting from increase in aircraft orders from EMIRATES and SINGAPORE AIRLINES, leading to average cost savings of 50% with minimal disruption to delivery schedule during learning curve phase.
• Negotiated contracts with Airbus UK and pioneered incentivised contracts with suppliers, leading to the business becoming the company’s most profitable.
• Led, mentored and motivated staff during challenging growth period through involvement and communication of strategy and implemented personal development plans, resulting in lower staff turnover than prior to growth period and receiving praise from the managing director.
Stress/Structural Engineer – Secondment to AIRBUS UK (Broughton)
• Analysed concessions (manufacturing non-conformances) on the single aisle and long-range aircraft (A320/A330/A340/A380) wingbox and communicated acceptance or repair solutions to the manufacturing department using the SAP software. I was subsequently selected by Airbus UK senior engineering management to undergo the delegated signatory authority training.
Stress Engineer – Secondment to AGUSTA WESTLAND HELICOPTERS
• Created and validated a 3D Finite Element Model of the AUGUSTA WESTLAND HELICOPTERS F/Lynx hoist support structure using MSc PATRAN/NASTRAN, subsequently using the results to carry out the detail stressing analysis.
Stress/Structural Engineer – Secondment to AIRBUS UK (Filton)
• Technically led the Airbus UK A340-500/600 Wingbox spar supply chain for the first SINGAPORE AIRLINES aircraft delivery. Provided technical solutions to suppliers to resolve low RFs, challenged existing methods to identify conservatism and ensured progress was in line with programme. I presented weekly progress reports to senior managers, resulting in an offer to join Airbus UK as a lead stress engineer.
• Developed Airbus UK structural analysis methods and tools for the A340-500/600 aircraft, leading to their use on the A380 programme.
• Undertook Finite Element Analysis of the A340-500/600 D-Nose to enable a comparison of data with Static and Fatigue testing to be made using MSc PATRAN/NASTRAN software.
• Used Airbus collection VAX programmes (FESPS, DAMTOL, WINGPACK etc.) to assess the impact of load changes and weight variants of the A340-500/600. The tools that I developed for this analysis became the standard across the project.
Stress Engineer (Including University industrial placement during 1999-2000)
• Carried out detailed stress analysis of the RAF Nimrod MRA4 avionics systems floor support structure for BAe SYSTEMS, leading to a position on the structural design review team.
• Undertook detail stress analysis of tooling jigs for tooling department using both hand calculations and FEA (ANSYS and MSc PATRAN/NASTRAN) software.
• MANCHESTER BUSINESS SCHOOL (U.K.) 2003 –2005
Master of Business Administration (MBA) – Executive MBA (Merit awarded)
Dissertation: Development of Hyde Group Engineering’s Manufacturing Support Business Strategy
• CRANFIELD UNIVERSITY (College of Aeronautics, U.K.) 2000 – 2001
MSc in Aerospace Vehicle Design
Dissertation: None-Linear Post Buckling Finite Element Analysis of Composite Anti-Symmetric
Laminates (Utilising MSc Patran/Nastran).
• UNIVERSITY OF SALFORD (U.K.) 1996 – 2000
BEng (Hons) - Aeronautical Engineering (1st Class degree awarded)
AWARDS & PROFESSIONAL ACCREDITATIONS
• Royal Aeronautical Society Student Prize (2000)
• Royal Aeronautical Society Project Prize (2000)
• University of Salford Student Award (2000)
• Microsoft Project Professional 2010 Certified Professional (MCTS/MCP)
• English (Native)
• German (Basic)
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