Summary
Overview
Work History
Education
Skills
Hobbies and Interests
Timeline
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Isaac S. Coulombe

Isaac S. Coulombe

Bow

Summary

Dynamic Manufacturing Engineer with extensive experience at Elbit Systems, specializing in opto-mechanical builds, precision bonding, integration testing. Proven track record in failure analysis and process improvement, successfully enhancing design and build of products. Adept at developing work instructions and stepping up to lead when the team needs it most.

Overview

5
5
years of professional experience

Work History

Manufacturing Engineer

Elbit Systems
Merrimack
06.2021 - Current
  • Placed on a Israel Defense Force program working my way to supporting 4 product lines (More than any other MFE on the program). Making me responsible for the work instructions, drawings, and all the failures associated with over 50 assemblies. This also made me the point of contact for 8 employees comprising technicians, assemblers, and optical bonders.
  • The majority of my experience is with opto-mechanical builds requiring precision bonding, with strict fit and finish tolerances.
  • Worked extensive overtime when the war in Israel started to support delivery of 6 full systems (220 assemblies per system) when we were only set up for 3.
  • During a 8 month period of time when we lost our Transition Program Manager (TPM). I stepped in to run the morning stand up meeting going over product progression, failures, and material shortages each morning. Management kept me in this role until our current TPM was hired.
  • Redlined over 100 drawings and work instructions. This included B.O.M consumptions, cross reference documentation from customer, milspec, and drawing requirements. Specifically torque, environmental testing, and integration procedures.
  • Designed my own mock unit for a product that was having extensive failures to install all of the engineering golden material inorder to screen and test components for troubleshooting root cause of failures. Worked hand and hand with our programs Sr electrical test engineer and operations from Israel for this.
  • Built extensive troubleshooting guides for each of the product lines I was responsible for. Reducing recurring failures and level of engineering involvement. The majority of engineering time was allocated to product and floor support during the heat of the Israel conflict so helped operators to solve their own problems reducing the level of engineering involvement.
  • From the ground up I developed a new chemical receiving process for highly critical chemicals for the entire SIGHTS program. Three specific chemicals needed a separate shipping and receiving process due to their very specific shelf life, temperature, and distribution requirements.
  • During the heat of the conflict in 2023 I was responsible for compiling the build data and building a capacity study inorder to get us to 6 full systems a month. This required a delicate balance of test equipment, thermal chambers, test time, build time, while dealing with the current failures at the time.
  • Built a consumption analysis for all the programs chemicals. Helping drive proper consumption with purchasing.
  • Work hand and hand with our planning department to fix our material kitting process. Material was being cut from our new IT systems on a as needed basis when we needed material a month before to meet our delivery schedule. We rewrote how we cut material kits to the floor by finding a different feature that moved us from demand based cutting to time based. This took the manual process of the team lead having to ask for kits to, them flowing out based on the required time to build - to ship.
  • Screened all of our failure data to identify what was hurting our first pass yield. Identified 3 software based failures that accounted for over 50% of our failure reports. Drastically affecting our first pass yield.
  • Supported other aerospace programs by screening and editing their process for defects and discrepancies while still supporting my programs needs.
  • Currently support our Joint Configuration Control Board (JCCB) reviews by collaborating for design change recommendations. I hold the meeting after to review and go over past and present JCCB meeting actions and responses from our team.
  • Work with Team Center, Jira, LN, and Segmes software daily.
  • Interface with rapid prototyping 3D printers to reduce load on our machine shop and support the manufacturing floor with 3D printed fixturing.
  • Work hand and hand with our machine shop. With my past machining experience and expertise we worked together on a lot of rework, helicoil, and tapping holes to support production.
  • Performed lots of leak test and leak test station validation / failures.

Manufacturing Engineer - Internship

Elbit Systems
Merrimack
12.2022 - 05.2023
  • Placed on a new developing program. Provided engineering sign off on build completion to product specs, found and updated work instruction discrepancies. Used skills developed from the Airborne Laser System program development to help create a more streamline transition and stock of parts to support the build.
  • Conducted thermal chamber characterization using a process and database I developed the previous year. Final analysis showed the number of at-risk-of-failure chambers were reduced substantially.

Manufacturing Engineer - Internship

Elbit Systems
Merrimack
06.2022 - 08.2022
  • Worked with a team of quality, manufacturing, and mechanical engineers and supported the development for the Airborne Laser Systems program in the early stages of production.
  • Worked on solving misaligned optical components and used high precision measurement devices to aid in realignment. Supported the metrology department by calibrating equipment, torque wrenches, pin gauges, chambers and thermal curing ovens.
  • Conducted a site-wide evaluation of risk due to the lack of documentation to support the calibration and maintenance of equipment for each program.

Manufacturing Engineer - Internship

Elbit Systems
Merrimack
12.2021 - 05.2022
  • Conducted site-wide thermal chamber characterization testing, fixing, and developed a process to repeat the tests to determine if each program thermal chamber(s) met product specification.
  • Developed a deep understanding of the various controllers and created SPM (Special Purpose Machine) manuals for each controller to be used for training technicians.

Manufacturing Engineer - Internship

Elbit Systems
Merrimack
06.2021 - 08.2021
  • Designed a floor plan layout for the new level 7 clean room.
  • Worked closely with Airborne Laser Systems (ALS) to develop and improve a manufacturing plan emphasizing critical areas of the manufacturing process such as possible bottlenecks. Heavily relied on the files I made to better present important data, specifically any major time constraints.
  • Developed multiple manufacturing procedures to ensure component safety.
  • Designed tooling, using 3D printing technology, for technicians to utilize during manufacturing.
  • Installed ESD monitors for the avionics division.

Postproduction Associate - Internship

Stone Machine
Chester
06.2020 - 08.2020
  • Split time between shop floor and classroom training.
  • Heavy use with precision measurement equipment (Tesa Height Gauges, Vision System, electronic comparator).
  • Operated a 4 axis CNC machine (Doosan Lynx Sub-Spindle Lathe).
  • Made custom parts out of steel and aluminum.
  • Part deburring, sanding, washing, finishing and assembly.
  • Trained on machine process, maintenance, Feature CAM software, reading part drawings.
  • Applied Design for Manufacturing (DfM) strategies.

Education

Bachelor of Science - Mechanical Engineering

University of New Hampshire
Durham, NH
01.2023

Associate Degree -

New Hampshire Technical Institute (NHTI)
Concord, NH

High School Diploma -

Concord Christian Academy
Concord, NH

Skills

  • Opto-mechanical builds
  • Precision bonding
  • Work instructions development
  • Failure analysis
  • Process development and improvement
  • SolidWorks proficiency

Hobbies and Interests

  • Completed self-taught rebuild and restoration of a 1980 Honda CB750 motorcycle.
  • Design and build custom furniture / gym equipment.
  • Completed a 4,200-mile motorcycle trip.
  • Volunteer at Calvary Bible Church's weekly infrastructure operations crew.
  • Participated in a short-term mission trip to Guatemala.
  • 10+ years of consistent workouts 5-7 days a week.
  • Avid reader.

Timeline

Manufacturing Engineer - Internship

Elbit Systems
12.2022 - 05.2023

Manufacturing Engineer - Internship

Elbit Systems
06.2022 - 08.2022

Manufacturing Engineer - Internship

Elbit Systems
12.2021 - 05.2022

Manufacturing Engineer

Elbit Systems
06.2021 - Current

Manufacturing Engineer - Internship

Elbit Systems
06.2021 - 08.2021

Postproduction Associate - Internship

Stone Machine
06.2020 - 08.2020

Bachelor of Science - Mechanical Engineering

University of New Hampshire

Associate Degree -

New Hampshire Technical Institute (NHTI)

High School Diploma -

Concord Christian Academy

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Isaac S. Coulombe