Dennis Heller
Jupiter,United States
Summary
SECRET CLEARANCE ADJUDICATED IN 2019
Manufacturing Engineering professional with extensive Aerospace experience. Seven+ years of experience designing and improving manufacturing systems within the DOD/Commercial Aerospace segment. Skilled in reviewing engineering specifications, creating manufacturing and supplier planning from the specifications, and maintaining configuration. Strong communication, analytical, and project management skills. Commitment to improving efficiency and effectiveness.
Overview
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1
Certification
Work History
Manufacturing Engineer III
Boeing
- BIMS ID - 02-002225851
- Reference: Martha Zink martha.l.zink@boeing.com 636-328-1603
- 777X - Composite Wing Assembly ME on First Article sub-assemblies.
- Updated Model Based Instructions (MBI) in Catia and revised and or updated planning in the CAPP system, based on Engineering, Quality and/or Operations inputs.
- Built and revised MBOMs from EBOMs.
- Assisted quality with coordinating manufacturing sequences with First Article Inspections (FAIs).
- Validated all planning in Teamcenter.
- Reviewed planning for compliance with Design for Manufacturing (DFM) requirements
Senior Project Manager
Boeing
- Assignment was working on the model change from 787-8 to 787-9 Dreamliner. There were multiple process improvement projects to increase throughput and reduce the operations footprint of the -8.
- Monitored manufacturing engineering project progress, identified risks and implemented corrective measures to drive success.
- Coordinated cross-functional teams to determine timely delivery and compliance of project requirements.
- Maintained schedules to meet key milestones at every project phase.
- Directed changes to project scope and cost and implemented appropriate change management processes to keep projects on track.
- Communicated project plans and progress to key stakeholders and project contributors
Senior Manufacturing Engineer
Kaman Aerospace
- Used lean manufacturing principles to develop, evaluate and improve detail part and assembly manufacturing methods.
- Applied statistical methods to estimate future manufacturing requirements.
- Selected manufacturing methods, fabrication and operations to develop and coordinated with shop floor, quality, engineering and supply chain.
- Identified problems and specific resolutions to fix defective, damaged or malfunctioning parts, assemblies, equipment and systems.
- Served as technical liaison between customer, manufacturing, quality assurance and vendor and supplier personnel to resolve technical and quality issues.
Lean Manufacturing Engineer
Sikorsky
- Developed acceptance criteria for vended parts.
- Identified appropriate methodology to shorten cycle time and achieve target margins.
- Authored manufacturing plans, bill of materials, production cell lay-out, and line balancing.
- Resolved technical and quality issues by collaborating with customer, manufacturing, quality assurance, vendors and supplier personnel.
- Swapped out materials and finishes in product line to alleviate performance issues and reduce corrosion.
Project Manager, Flight Test
Sikorsky
- Designed documents and statements of proposals, lead times, technical costs and budgets and statements of work to manage supplier development efforts.
- Supervised product development and introduction of prototypes for Instrumentation data acquisition designs.
- Managed supplier development efforts through engineering design, technical producibility, manufacturing reviews and development of solutions.
- Outlined work plans, determined resources, wrote timelines, and generated initial budgets as part of project scope determination.
Education
MBA - Operations Management
Jacksonville University
Jacksonville, FLBachelor of Science - Mechanical Engineering
Florida State University
Tallahassee, FLSkills
- Boeing SAP, PDM, CAPP, CATIA, MESci, TeamCenter
- Process Planning - detail and assembly
- Process Validation
- EBOM, MBOM
- Root Cause Analysis
- Non-Conformance Reporting resolution
- Supplier Support
- LEAN, Six Sigma
- Project Management
- Configuration Management
- First Article Inspections (FAIs)
Additional Information
- Authored an automated vendor technical help system to document and resolve issues in a timely and consistent
manner, between legacy engineering and updated engineering requirements. The tech help form incorporated fields
for important information (part number, engineering drawing number, revisions, specification numbers and revisions,
contract number, issue description, priority, history). The new forms and procedures were incorporated into the
Supply Chain procedure for all suppliers and vendors. The historical data was used to identify and resolve conflicting
areas for process improvements in tooling, material specification and engineering drawings. Reduced overlapping of
issues (and associated wait times) by 80%. - Developed a semi-automated algorithm for the engineering interrogation (drawings, Cad, Models, material specifications) and transferring the product information into vendor instructions and first article inspection reports for detail and assembly parts. This significantly reduced unintentional omitted or conflicting engineering characteristics. Reduced flags (and resulting rework and wait times) for missing or conflicting information by 90%.
- As a member of the engineering change board, developed a process improvement of a formal process flow map for ensuring proposed engineering changes were reviewed by the appropriate functional areas and suppliers/vendors for producibility and schedule impacts prior to change board reviews. All issues were documented and resolved, and a risk value was determined (schedule, technical, quality, costs) for each proposed change. Upon team approval, configuration management incorporated the changes with a pre-release to manufacturing engineering for updates and release into the manufacturing/vendor environment. This decreased the average engineering change incorporation time by 75%
.
Certification
- ASME BRONZE LEAN
- ASQ GREEN SIX SIGMA
- Project Management Institute PMP
- Systems Modeling MIT
- Systems Thinking Cornell
Timeline
Manufacturing Engineer III
Boeing
Senior Project Manager
Boeing
Senior Manufacturing Engineer
Kaman Aerospace
Lean Manufacturing Engineer
Sikorsky
Project Manager, Flight Test
Sikorsky
MBA - Operations Management
Jacksonville University
Bachelor of Science - Mechanical Engineering
Florida State University
Business
Heller Consulting Services LLC L16000113657
Jupiter, Florida
May, 2008 - 2022
Aerospace Sector - DOD and Commercial
Platforms Supported
- Boeing – C-17 Globemaster – Structural wing retrofit process assembly planning, configuration management.
- Boeing - A-10 Warthog – Flight control surface upgrades assembly planning. NCR resolution.
- Boeing – 787 Dreamliner – Barrel Tape Lay-up and Stiffener process improvements to increase through-put.
- Boeing - 777x - Wing Assembly process improvement planning
- Bell – AH-1Z Cobra – complete assembly of new fuselage design. Detail and assembly planning, configuration control, supply chain engineering.
- Northrop Grumman- E2D Hawkeye – structural upgrades- Detail part planning, FEMA, FAIs
- Sikorsky – UM60H Weaponized Blackhawk – Ground and Flight Test - Project Management
- Sikorsky - CH-53K King Stallion - Ground and Flight Test - Project Management
- Sikorsky – VH-2 Marine One - Ground and Flight Test - Project Management
Dates of Selected Assignments
- BOEING, Charleston SC, 4/2012-9/2012, St. Louise, MO, 6/2021-5/2022
- KAMAN AEROSPACE, Jacksonville Florida 4/2008-11/2010, 3/2011-9/2011
- SIKORSKY AIRCRAFT, Troy, Alabama, 10/2011- 3/2012, 5/2020 – 2/2021, Jupiter, Florida, 5/2014-8/2016, Patuxent River, MD, 6/2019 – 2/2020