Trevor Sutton
Tuscumbia,Al
Summary
Results-driven CNC Programmer and aerospace manufacturing leader with 25 years of experience supporting defense, aerospace, machining, fabrication, and aircraft operations across complex DoD programs. Extensive experience developing and optimizing 3-axis, 4-axis, and 5-axis CNC machining programs using Mastercam while supporting production machining of aerospace components and assemblies. Proven expertise interpreting engineering blueprints, CAD models, and GD&T requirements to create efficient machining strategies, reduce cycle times, improve quality, and enhance production throughput. Demonstrated success leading operational and manufacturing initiatives for Northrop Grumman Aerospace Systems, including implementation of advanced CNC machining technologies, process optimization efforts, and continuous improvement programs resulting in over $550K in annual savings. Strong background in machining aerospace materials, troubleshooting G-code and post-processing issues, supporting shop-floor prove-outs, and collaborating cross-functionally with engineering, quality, and manufacturing teams in high-performance production environments. Experienced in supporting aerospace manufacturing operations involving precision tolerances, complex geometries, and mission-critical components while maintaining compliance with OSHA, quality, and defense manufacturing standards. Eligible to maintain U.S. Government Secret and SAP clearances.
Overview
23
23
years of professional experience
1
1
Certification
Work History
General Manufacturing Manager – Operations
Northrop Grumman Aerospace Systems
Iuka, MS
09.2023 - Current
- Lead strategic manufacturing operations supporting four machining centers across five departments for multiple Department of Defense weapons platforms.
- Support CNC machining operations through process optimization, manufacturing planning, workflow coordination, and continuous improvement initiatives focused on quality, cost, and schedule performance.
- Implement advanced CNC machining technology and staffing realignment initiatives, resulting in over $550,000 in annual cost savings.
- Collaborate with engineering and process owners to improve machining procedures, optimize manufacturing workflows, and implement best practices for aerospace production operations.
- Track manufacturing performance using EVM metrics to identify deviations, reduce risk, and improve operational execution.
- Streamline inspection and production verification processes, reducing associated costs by 56% and equipment downtime by 62%.
- Support troubleshooting of manufacturing and machining-related issues while coordinating corrective actions for non-conformances and quality findings.
- Drive continuous improvement initiatives focused on productivity, machining efficiency, throughput, and operational excellence.
- Coordinate with leadership teams to align manufacturing initiatives with broader aerospace production and business objectives.
- Led cross-functional teams to optimize manufacturing processes and enhance operational efficiency.
- Implemented lean manufacturing principles, resulting in significant waste reduction and increased productivity.
Production Manager
United States Air Force
Elgin, AFB
03.2020 - 06.2023
- Directed aerospace maintenance and production operations supporting 55 F-22 and 17 T-38 aircraft across multiple maintenance organizations.
- Developed production schedules and coordinated over 7,000 annual maintenance actions to meet operational readiness requirements.
- Led Lean and Six Sigma process improvement initiatives that increased throughput, reduced cycle times, and improved operational efficiency.
- Coordinated with Aircraft Manufacture depot teams to develop and certify a new aircraft bulkhead corrosion repair process, saving 1,500 annual downtime hours.
- Assessed KPIs and operational metrics to identify production trends and implement corrective actions supporting mission performance.
- Championed workplace safety, quality compliance, and process discipline in accordance with AFI 21-101 standards.
- Led production planning to optimize workflow and enhance operational efficiency.
- Managed cross-functional teams to ensure adherence to quality standards and safety protocols.
Fabrication Flight Manager/ Lead CNC Programmer
United States Air Force
Tyndall, AFB
02.2016 - 03.2020
- Directed fabrication, machining, structural, welding, and aerospace repair operations supporting F-22 and T-38 aircraft maintenance activities.
- Oversaw maintenance and security operations for $48M in aerospace repair facilities, tooling, and support equipment.
- Managed staffing, production scheduling, technical training, and operational readiness for 38 fabrication technicians.
- Developed process improvements that reduced low-observable maintenance flow time from 320% to 90% through workflow optimization.
- Led a 20-member production team manufacturing naval targeting pod components, supporting joint-service operational requirements while saving $100K annually.
- Directed OSHA, EPA, and HAZMAT compliance activities while leading root-cause investigations and corrective action initiatives.
- Coordinated mission planning and execution for diverse aerospace operations.
- Oversaw flight operations ensuring compliance with safety regulations and operational protocols.
CNC Machinist & Programmer
United States Air Force
Mountain Home, AFB
05.2008 - 02.2016
- Develop and optimize complex 3-axis and 5-axis CNC machining programs using Mastercam, FeatureCAM, and Fusion 360 for aerospace and precision-machined components.
- Analyze CAD models, blueprints, and GD&T requirements to determine optimal machining sequences, tooling strategies, and work-holding methods.
- Create and refine CNC tool paths to improve machining efficiency, reduce cycle times, and maintain dimensional accuracy on tight-tolerance components.
- Troubleshoot and debug G-code, post-processing, and machining issues during machine setup and production prove-outs.
- Collaborate with machinists, engineering, and quality personnel to improve machining reliability, process consistency, and production throughput.
- Reduce tooling costs by 18% through optimized cutting strategies, toolpath improvements, and machining process refinements.
- Support machine setup activities including tooling selection, offset verification, fixture alignment, and first-piece validation.
- Perform preventive maintenance and machine performance monitoring to minimize downtime and maintain reliable production capability.
- Operated CNC machines to produce precision components for aerospace defense applications.
Manual/CNC Machinist & Setup Operator
United States Air Force
Mountain Home, AFB
08.2003 - 05.2008
- Operated CNC milling and turning equipment producing precision aerospace and industrial metal components while maintaining high production efficiency.
- Set up CNC/Manual machines, loaded and verified programs, established tooling offsets, and ensured compliance with engineering and quality specifications.
- Supported machining operations involving complex tolerances and detailed blueprint requirements using GD&T standards.
- Conducted first-article, in-process, and final inspections utilizing precision measurement equipment including micrometers, calipers, and optical comparators.
- Participated in setup-reduction and process-improvement initiatives that reduced production lead times by 23%.
- Assisted with troubleshooting machining issues and implementing corrective actions to improve quality and machining consistency.
- Trained and mentored junior machinists and operators on setup procedures, tooling selection, machine operation, and G-code fundamentals.
Education
Bachelor of Arts - Organizational Management
Ashford University
Phoenix, AZAssociate of Applied Science - Metals Technology
Community College of The Air Force
Langley, AFB Skills
- 3-Axis, 4-Axis, and 5-Axis CNC Programming
- Mastercam CAM Programming
- G-Code and M-Code Troubleshooting
- Toolpath Optimization and Post Processing
- Fixture and Work-Holding Strategy Development
- Process Planning and Cycle Time Reduction
- CAD/CAM & Engineering Interpretation
- Blueprint Reading, Technical Drawings & GD&T Interpretation
- Trigonometry and Geometric Calculations
- Tool Selection and Cutting Strategy Optimization
- AS9100 Manufacturing Environment
- OSHA, EPA, and HAZMAT Compliance
- Continuous Improvement and Lean Manufacturing
- ERP Systems and Manufacturing Reporting
- Microsoft Office Suite
- Experience Supporting High-Tolerance Aerospace Components
- Proven Leadership in Manufacturing Operations and Team Development
- Strong Communication and Cross-Functional Collaboration Skills
- Ability to Support Classified and Special Program Aerospace Environments
Websites
Certification
- Active DoD Clearance Eligibility: Secret and SAP
- Aircraft Metals Technology — Aberdeen APG, MD
- Advanced Metallurgy — Aberdeen APG, MD
- Advanced Heat Treating and Machining Methods — Sheppard AFB, TX
- Autodesk certification for FeatureCAM & Fusion 360.
Timeline
General Manufacturing Manager – Operations
Northrop Grumman Aerospace Systems
09.2023 - Current
Production Manager
United States Air Force
03.2020 - 06.2023
Fabrication Flight Manager/ Lead CNC Programmer
United States Air Force
02.2016 - 03.2020
CNC Machinist & Programmer
United States Air Force
05.2008 - 02.2016
Manual/CNC Machinist & Setup Operator
United States Air Force
08.2003 - 05.2008
Bachelor of Arts - Organizational Management
Ashford University
Associate of Applied Science - Metals Technology
Community College of The Air Force