William Fetner

Job Mission:

. Anticipate & Correct Production Issues.

. Reduce production costs.

. Establish zero error production.

Primary accomplishment, Developed new Liquid formulation for creating complex molds with unusual configurations. Over 50,000 in savings 1st year.

Developed new tools to reduce damage to end-use products during manufacturing. Over 100,000 in savings 1st year.

Developed new and improved manufacturing processes to reduce injury and better safety.

Daily responsibilities:

Review and improve the production floor matrix.

Identify areas for lean manufacturing techniques, concepts and processes. Managed daily safety and product improvement meetings.

• Applied engineering estimating and proposal development, to include, creating engineering bill of materials (BOMs), writing supplier RFQs, obtaining supplier quotations, developing preliminary manufacturing process flows, Identifying tooling solutions, and estimating factory labor hours through all phases of manufacturing process.
• Proficient in processing of autoclave cured composite materials, including hand lay-up, vacuum bagging techniques, adhesive bonding, core splicing.
• Defined requirements for development of equipment, robotics, Lay-up molds, Vacuum Holding Fixtures, Shop Aids, Positioning fixtures, Go-No-Go inspection tools required for the manufacturing of new products.
• Obtained tooling quotations from internal and external sources.
• Managed cross-functional team in transitioning new product from design to manufacturing at targeted rate.
• Sourced composite materials and processes that improve component properties, reduce costs, and increase efficiency by performing trade studies and testing.
• Applied safety, failure mode and effects analysis (FMEA), Process Capability and Total Product Maintenance (TPM) for new and existing equipment.
• Researched and tested design feasibility and operation of equipment, components and systems.
• Managed manufacturing projects and program services to handle engineering and project metrics.
• Reviewed products for compliance with Design for Manufacturing (DFM) requirements.
• Applied project management metrics and tools in oversight of engineering and manufacturing projects and program services.
• Completed purchase analysis to analyze customer engineering drawings and specifications.
• Coordinated selection of manufacturing methods, fabrication and operation of product designs.
• Applied Industrial Engineering methods for factory flow models, capacity and throughput models, and production simulations.
• Applied Machining and composite fabrication processes and technologies.
• Defined tooling requirements for lay-up molds and mandrels, trim & drill fixtures, and manufacturing aids used in fabrication of complex composite structures.

• Removed/reinstalled interior linings, cargo bay liners, floor panels.
• Removed/reinstalled lavatories, galleys, seats, windscreens.
• Removed/Re-skinned doors/reinstalled.
• Utilize OEM / Engineering drawings to modify structures.
• Repair, replace, rebuild aircraft structures.
• Perform heavy sheet metal structural tasks such as removing, repairing or replacing floor beams, bulkheads, stringers, frames, chords and any other primary structural parts.
• Locate and mark dimensions, layout patterns, create templates ,fabricate parts, repair or replace skin and stiffeners, stringers, frames, brackets, fairings, retaining strips, floor beams, extrusions and seat tracks.
• Repair, replace, rebuild any damaged aircraft structures & flight surfaces.

SKILLS AND KNOWLEDGE:

• Extensive knowledge in repairing & manufacturing all areas of aircraft / helicopters / rockets.
• Developed repair schemes utilizing SRM or engineering data.
• Communicate effectively with other maintenance / engineering personnel at all levels by keeping co-workers and leadership apprised of work progress and difficulties as they arise.
• Completed job assignments in timely manner.
• Read & interpreted manufacturer airline maintenance manuals, service bulletins, drawings and other specifications to determine feasibility of method for repair, replacement or modification.
• Conducted operational tests.

• Golf Club development with advanced materials: Worked with a carbon fiber company to use carbon fiber recycled square cubes to manufacture long range golf drivers. Created all tooling for manufacturing process.
• Worked with Leading Edge Aviation company to design and produce a gyro controlled work platform that’s suspended beneath aircraft. Its use was for performing aerial work on wind mills and high tension lines and large antennas.
• Provided forensic analysis of project documents, outlining possible delays and problematic aspects of planned investments.
• Monitored project activities and verified team adherence to project budget, business standards and regulations.
• Developed production plans, integrating cross-functional teams to streamline operations.
• Consulted with Subject Matter Experts (SMEs) to resolve technical issues that arose during production.
• Finalized project plans and obtained approval from clients.

747 Everett facility:

• 747-8F & 747-8I Wing / Body structures, Provided red line / tag support. Corrected production & engineering anomalies. Assisted in FAA certification of aircraft. Approved Wing & Fuselage tooling / structures plans for engineering and planning errors.
• 747-8I Project Interiors:

Provided forward looking support to anticipate issues in merging interior monuments at all workstations/control codes. Prepared Technical Decision Records (TDRs) that Evaluate, summarize, and make recommendations to airline customers related to Boeing Service Bulletins.

Prepared Engineering Orders (EOs), coordinated Job Card development, to support the incorporation of Boeing Service Bulletins on customer aircraft.

Coordinated multiple elements of the EO process with Maintenance Programs, Maintenance Planning, Materials Services, and Customers.

• 787-8 Advanced Developmental Composites:

Assessed in correcting carbon fiber flap issues in Australia’s production line. (Root cause analysis.

• 787-9 Advanced Developmental composites:

Horizontal stabilizer integration with R&D, . BL40 ME stakeholder. In charge of developing the processes for installing the carbon fiber BL40 riblets. Signed off on all aspects of drilling methods and assembly processes and Manufacturing layup of the riblets. Signed off on all aspects of drilling methods and assembly processes and Manufacturing layup of the riblets, assisted in trouble shooting layup issues in planning. Developed gage reducing of material with C&C machining of Parts.

• 787-9 Advanced Developmental Composites.

Floor beams. ME Liaison, assisted in working through the development planning, fabrication and assembly. Assisted in FAA certification, Worked with all aspects of tooling and tooling issues. Assisted in trouble shooting layup issues in planning. Worked in Gage reducing of material with C&C machining of Parts.

(Root cause analysis.) Worked extensively with developing the NOODLE that strengthens the T cord connecting the floor beam.

Worked with FAA Part 121 and Part 145 regulations related to operational and maintenance requirements for FAA regulations.

• Created plans and communicated deadlines to ensure projects were completed on time
• Collaborated closely with internal stakeholders (M&P engineers, test technicians, manufacturing engineers, production management, and design/analysis engineers) to incorporate requirements into the production system.
• Universal Product Review and Commercial Product Review certification.
• Worked with Product Data Management (PDM), Model Based Engineering (MBE), CATIA, ENOVIA, Configuration Management Professional (CMPRO), GOLD Enterprise Service Platform (GOLDesp), and Common Assignment, Substantiation, Technical Log and Evaluation (CASTLE) database.

Assembled 32' Rocket PPV-1 prototype, worked through production issues with engineering.

• Experience with launch vehicle, aircraft, or spacecraft manufacturing and integration.
• Experience with safety critical systems.
• Utilized 3D CAD software, 2D and 3D engineering drawings
• Applied best practices regarding safety, in use of pneumatics, hydraulics, avionics, and cleanliness
• Utilized common NDT methods, including visual, dye penetrant, ultrasound, x-ray, CT scan, Eddy Current, XRF scan
• Always committed to culture of safety.
• Worked in cross functional environment to develop vehicle integration solutions

• Monitored technology infrastructure against core standards to provide technical assessment and advisory services.
• Advised project managers on simultaneous technical workstreams, aiding in alignment of broader business goals.
• Advised on how to secure intellectual property while in process of Manufacturing.
• Standardized technical operations reporting parameters to reduce wasted and redundant effort across multidisciplinary teams.
• Offered insight into standard methodologies and common obstacles faced by competing companies, based on experiences with past clients and third-party research.
• Identified and demolished development roadblocks to prohibit slowed operations or halted productive development efforts.
• Enforced use of prescribed technical procedures, designing monitoring protocols to confirm compliance with guidelines.
• Collaborated with personnel to provide updated knowledge regarding industry application standards and specifications.
• Provided ad-hoc security and infrastructure services based on organizational expectations, training and pre-deployment certification and other clearances.
• Communicated project status to stakeholders, authoring reports to provide up-to-date overviews of ongoing progress.