• Populate the Quality & Inspection element, including the allocation of time & cost, of numerous multi-million pound Technical Proposals (detailed quotations)
• Creation the company's First Article Inspection (FAI)/ First Article Verification  (FAV) strategy and system in adherence with AS9102
• NADCAP assessment and gap analysis
• Develop business case and detailed technical requirement specifications for the purchase of inspection facilities including the Non Destructive Testing (NDT) facility (£1million), Coordinate Measuring Machine (CMM) in a controlled environment (£750,000) and created the machining performance acceptance criteria to ensure customer tolerances are achievable
• Point of contact for all Quality related enquiry's for all three F-35 airframe contractors
• Developed the JSF specific Measurement Systems Analysis (MSA) philosophy to ensure the most suitable inspection equipment is used.

Project Two

Project:

The Project was to establish a robust site wide Metrology system that will define the approach of the inspection policy throughout the SDD phase and future LRIP stages of F-35 (Joint Strike Fighter) aircraft build. Ensuring measurement activities are completed using the optimum metrology device and process. In addition, understand process capability throughout the various businesses both internal and external, and generate quality plans that will control the build of the three major assemblies (AFT Fuse, Vertical & Horizontal Tails) ensuring both Key Characteristic (KC's) and Build Verification (BV) inspection requirements are completed throughout the build.

This was achieved through the use of Measurement Systems Analysis principles to ensure the best solution per measurement activity was chosen, which identified current measurement failures and provided the necessary information to make the correct measurement decision. Process capability was developed to include the QEDM system that I developed during a previous project (see blow), together with advanced statistical and matrix reporting methods to provide real time statistical data throughout the F-35 production and assembly.

• Understand and document BAE Systems current site wide Metrology capability
• Conduct various analysis into current and potential inspection device selection including gauge Repeatability and Reproducibility (Gauge R & R) tests to determine best inspection device per key characteristic
• Produce business cases for the purchase of new inspection equipment
• Create a site wide intranet based system of storing, viewing and analysing digitally created data from many sources such as CMM, Laser Tracker & various hand held devices to facilitate a paperless process.
• Determine BAE Systems Product/ Process capability for Composite, Fabrication, Machining, & Assembly business areas
• Investigate root causes failings for initial aircraft and introduce corrective action processes
• Point-of-contact (POC) for BAE Systems Process Capability initiative and liaise with Lockheed Martin, Northrop Grumman counterparts in a weekly NetMeeting.
• Develop Inspection Quality Plans for the JSF AFT Fuse, Horizontal Tail, & Vertical Tail assemblies
• Specify measurement requirements throughout build of aircraft including measurement tool, frequency of check, Datum Scheme/ Set Up and subsequent use of recorded data

Project Three

Project:

BAE Systems has purchased and/ or developed quality control systems that allow for the inspection, test and statistical analysis of product and/ or process capability for the Eurofighter Typhoon, and future fighter aircraft. However, the various business units throughout the organisation each store, view and analyse data in various methods and formats, thus creating an unmanageable digital data system with no strong understanding of current manufacturing processes and methodologies.

Using my knowledge of various Quality tools I have been assigned the task of creating a Quality Engineering Data Management (QEDM) system. This system will be used throughout the organisation to reduce the different data formats, storage locations and facilities with a vision to provide the ability to view stored data at any time. Further to this, the ability to analyse the data that has been stored whilst using the Intranet/ Internet to gain an in-depth view of current manufacturing processes and methodologies. This system enabled a paperless environment to be instigated and a clear understanding of manufacturing capability.

• Design a standard format for all digitally created data (CMM's, Laser trackers and other measurement devices) to be used throughout the organisation
• Develop a system to store such digitally created data from anywhere in the organisation into one single storage facility
• From the above, create the ability to view all stored data from anywhere in the organisation in real time without the need of paper printouts
• Provided the ability to analyse the data to provide basic and in-depth process capability/ performance reporting functionality in 'Real Time' at a touch of a button without the need for dedicated SPC software 

Key Benefits:

• A reduction in valuable networked hard disk space usage, through the insertion of a dedicated QEDM server and removing the need and/ or accidental creation of duplicated data files.
• Predicted 50% (average) time saving in data retrieval
• Predicted saving on re-inspection activities, a time consumption of 1000 man hours per year
• Predicted saving in problem solving initiatives equating to 10% (average) reduction per year
• Savings gained through the reduction of concessions
• Reduction in the manufacture of scrapped components
• Cost saving due to reworked products reduced

Project Four

Project:

Further to my previous role at MTS, as the Quality Engineer it was my responsibility to ensure the smooth operation of the inspection department and team of 3 inspectors. During this time I also established a comprehensive Quality Control system using techniques such as Statistical Process Control (SPC), Scatter Plots and Bar Charting.

From this information, a detailed understanding of manufacturing capability could be delivered to the management team to highlight both strengths and weaknesses throughout the various manufacturing processes. Investigative teams where then set up to analyse the areas of concern and Process Improvement projects issued to improve capability.

Other Quality activities undertaken:

• Create procedural documents in support of QMS
• Develop full Metrology System
• Commence the Supplier Appraisal System
• Creation of customer quotations (Quality related context)

Project Five

Project:

MTS Precision is sub contract precision engineering business established in 1959. MTS turned parts are in constant use in critical situations such as offshore safety systems, petrochemical process plant, electronics applications and pharmaceutical manufacture.The use of such products requires stringent inspection practices in order to guarantee customer product satisfaction.

 My primary role at MTS was to established the Inspection department from scratch, and subsequent inspection systems in accordance with ISO 2859 (BS6001) Sampling procedures, and develop a training plan for all employees to improve the company skills-set. This enabled MTS to become a leading precision engineering business and compete within the market.

Other Quality activities undertaken:

• Established calibration system
• Developed product measurement plans
• Contribute to MTS Quality Management System (QMS)
• Extensive use of measuring equipment (CMM, Laser, Hand Held, Non Destructive)

six sigma, FMEA, SPC, statistical Process Control, Quality Assurance, Quality Contractor, Quality Engineering, Metrology, measurement systems analysis, MSA, consultant, contractor, aerospace, oil gas, engineering improvement, PPAP