1. GARY F. SCHAFFER
824 Bridle Trail
Saginaw, TX 76179
(214) 437-2037 cell
E-mail: kansassch@hotmail.com
OBJECTIVE
Seeking an opportunity as a Manufacturing Engineer, Tool Engineer, Project Manager, Liaison Engineer,
Industrial Engineer, Configuration Management, Liaison, MRB and Modification to perform all or any of the
following duties and responsibilities with corrective actions on rejection tags for metallic, structural, electrical,
composites, functional and flight tests , root analysis studies, troubleshooting, compliance, validation, auditing,
assessment, verification of assembly & installation to concurrent engineering and production changes to ensure
quality with safety and maintaining the schedule. Lean manufacturing with 5S, Six Sigma, Kaizen principles for
subassembly work cells to accelerate production, balancing, documentation of processes.
SUMMARY OF QUALIFICATIONS:
Engineering Experience: Manufacturing Engineer, Industrial Engineer, Liaison Engineer, Process Engineer
Analyst, in Project, Liaison and Material Review Board apply engineer fixes for rejectable conditions per company
special repair manuals, functional test, analyze production anomalies, establish lean manufacturing work cells,
installation of integrated systems of people Planning & Production Control produce unit cost charts, cycle plans,
recovery plans, schedule tool tryouts, tool down time, analyze current process steps, installation jobs sequence,
pre-planning, shop forecast, work transfer package, quality cycle phasing, chart shops production flow, materials
and assets using digital design, production line balancing and documentation of shop processes. Industrial
Engineer produce unit cost charts, recovery plans, schedule tool tryout and tool down time, streamline process
steps, root analysis studies, job function sequencing, pre-planning, shop forecast, cycle plans, work transfer
packages, cycle phasing and chart the production flows, lean mfg, experience with the
technical/professional/functional knowledge and skills to do the job at a high level of accomplishment.
Management Skills: Project management, chairperson for Configuration Management, Interchangeable and
Replaceable Committee, Change Board chair, Team Leader directing Design Build Teams, Integration Production
Teams, Program Planning & Control, Project Planning, Liaison groups; managing schedules. Experience has led
to knowledge of strategic planning, staff development, project execution, Catia and MS Office software.
Computer Skills: Access; Advantage; Baan/ERP; BOM; CAD; CAPP; CATIA V5; CDS; Crosspoint; CICS; CTOL;
DCAC; Delmia; Docushare; ELR; ENOVIA; ETS; Exceed; Excel; Exchange; Excite; Extra; FCSS; FSS;
GraphTalk; IMS/IDB; IVT; KBE; KGV1VM; Matrix1; MDS; MECA; MES; Mapper; Milestones; MRLS; MRM; MRP2;
NetMeeting, OIR; OLP; Outlook; PDM; PowerPoint; PRD1; Pro E; Project 98; PSDS; REDARS; Rumba; SAP;
SharePoint; Slate; Solumina, SPC; TeamCenter; Velocity; WAVE; Windows XP; Webex, Windchill; Word.
EMPLOYMENT HISTORY
GKN contractor (Cyient) in Orangeburg, SC 7/2015 – 11/2016 as M.E. to setup a new fabrication facility in an
empty warehouse building with (5) giant 5-axis CNC equipment, (3) Spin Form machine, one of the largest Heat
Treat furnace, (13) tanks of Anodize, etch process, FPI, large ovens, robotic grind and polishing cell, paint,
procoat booths, ATOS inspection, receiving and shipping area. Coordinating with Automation Engineer, vendors.
Boeing contractor at Vought in Dallas, TX. /Charleston, SC. (SRI) 4/2009 – 7/2015 Mfg. Engr. Responsible
for Test Plans on 787 ECS, ICS, Fire Suppression, Potable Water and Vacuum Waste systems. Write existing
Acceptance Test Procedures process to Boeing requirements with current Engineering changes, tooling &
specifications. Transferred to Tooling as a Project Manager/Liaison Tool Engineer responsible for sections 47/48
tools and test equipment. Manages tools from initial design to end use disposition. Investigates and resolves
manufacturing related issues. Perform producibility assessments for tooling designs. Provide improvements and
safety inputs to design, manufacturing processes and manufacturing technologies to meet cost and schedules.
Work with the core group with the transition from Vought to Boeing integration, updating and rewriting Tool Usage
Instructions and Procedures into the Boeing format. Tooling Project Manager coordinate with vendors to design.
Keystone Helicopter Coatesville, PA. (ESG) 9/2008 – 4/2009 Mfg. Engr. Responsible for ATP’s on S-92, H-92,
S-76C, S-76D prototype create and rewrite existing Acceptance Test Procedures process to obtain a Keystone
Helicopter Production Certificate and update AOS’s in aircraft workbooks to current Engineering changes, tooling
and specifications. Work with Sikorsky Helicopter for the transition of the commercial helicopter programs. Design
and install quality control process sampling systems, procedures, techniques in a safe and efficient manner.
Boeing Everett, WA. (PDS) 12/2006 – 9/2008 Pre-Integration Mfg. Engr. Responsible for pre-integration on 787
Final Assembly & Delivery creating out-of-sequence Installation Plans for our global partners’ incomplete products
using CATIA V5, ENOVIA, Delmia, Velocity, WAVE, IVT, Word, Excel, Adobe, Access, PowerPoint, global
partners’ workbooks, etc. And implementing lean manufacturing using 5S, Six Sigma, Kaizen principles, etc.
to create a more efficient plan that delivers a superb deliverable product for our internal and external customers.
Boeing Everett, WA. (CTS) 9/2005 – 12/2006 Integration Engr. Responsible for integration on 787 Flight Deck
with global partners and Boeing, volume manager, product definition, Flight test and Spares requirements, analysis
interferences using CATIA V5, Mapper, Slate, ENOVIA, Delmia, IVT, Excel, Access, PowerPoint, Excel report, etc.

2. GARY F. SCHAFFER
Page 2 of 2 EMPLOYMENT HISTORY (continued)
Gulfstream Aircraft Brunswick, GA. (Comforce) 2/2005 – 9/2005 Mfg Engr/Industrial Engr responsible for
G450, G550 final phase Completion Center & Service Center using CADAM, CATIA V5, V4, CORRIDOR
systems, responsible to direct, track, report on the delivery performance for identified suppliers, reviews schedule
changes, assesses impact. Analyze production limitations and standards, recommend revision of specifications.
Lockheed Martin Aeronautics Ft. Worth, TX. 8/2002 – 2/2005 Mfg. Engr. responsible for F-16 program Mate-
To-Delivery including Engine Preparation and Installation, Weapons Package and Flight Test using the DD250
delivery process, responsible for disposition of non-conformance hardware which the repairs are not covered in
the Standard Repair Manual and provided rework instruction and drawing interpret drawings to the shop floor.
Boeing Commercial Airplane, Renton/Everett, WA. (PDS) 4/2000 – 1/2002 Mfg. Engr. Wing Responsibility
Center responsibility for job audits on the model 737/757 systems testing for the wing control surfaces with
functional tests of hydraulic systems. Interior Responsibility Center for the 747/767 Ceiling and Sidewall Panels.
Training in IntraLink classes on the DCAC system implementation using PDM, CAPP and ERP/Baan planning.
M.E. shop support using root analysis, troubleshooting composite panels for Boeing single & twin aisle models.
Lean manufacturing using the Six Sigma & Kaizen principles discipline for continuous improvement in production.
Crestview Aerospace Corp. Crestview, FL. (Quantum Resources) 2/1999 – 4/2000 Production Engineer
develop Manufacture and Inspection books for modification, re-engine C-130 military turbo prop aircraft sequence
job tasks and develop a BOM. Value Stream, 5S and mapping the planning processes using Advantage, Project
98 system and Pro E Drawings. Wrote Time Compliance Technical Order and applied military standards per MIL-
M-28784B & MIL-T-38804A for modifying the C130 military aircraft. Knowledge Air Force modification procedures,
Resource Library, terminology and Fixed Base Operations; aircraft maintenance/logistics processes; coordinate
the Retrofit Instructions Service Bulletins and provide 24 hours Product Support to the field service team RAMS.
Computer skills: Advantage, CAD, Excel, Lotus, MRP2, Pro E, Project 98, RAMS, Windows 98, Word 97, etc.
Boeing Commercial Airplane, Renton, WA. (ADECCO) 6/1998 – 1/1999 Manufacturing Engineer for special
Projects to establish a team to eliminate the out-of-sequence; additional reworks and functional test rewrites on
the model 737 final assembly lines. Developed and maintained production Bar Charts, recovery plans, process
plans, MRB, make/buy policy evaluation, visibility of shop floor control system, shop status, labor efficiencies,
shop documentation, Just-In-Time (JIT), MOST concepts, Pro E Drawings and facilitate analytical techniques.
Northrop/Grumman, Lake Charles, LA. (RMI, Resources Management International) 12/1997- 6/1998 Liaison
Engineer for modification and refurbish the old Boeing model 707 into a Military J-STARS aircraft. My duties,
responsibilities were flight and functional test Technical Orders; write O&A's (Over & Above), MRB corrective
actions, prepared and maintain work instructions for the J-STARS military program using the IMPCA system
convert to paperless manufacturing system, control the aircraft design objectives and document as-built
configuration. Lake Charles did the refurbish and modification operation and Melbourne, FL perform fabrication
instructions to the develop the kit lists and planning the flow of work documents Pro E Drawings and kit parts.
Raytheon Aircraft, Wichita KS. (Kirk-Mayer) 1/1997 – 11/1997 Mfg. Engr. execute standard planning, reports
on composite processes, providing support in the development and maintenance of work program processes with
Autoclaves, Bill of Materials, Production sketches, illustrations and the functional tests for control surfaces and to
ensure that goals and objects are accomplished within prescribed time frames and funding/budget parameters for
new programs Premier1 and the J-PATS by performing regular analysis of project status and their schedules.
Boeing Commercial Airplane, Seattle, WA. /Wichita, KS. 12/1978 – 1/1997 Mfg. Engr., Liaison Engineer
develops, implements and maintains various shop plans; Liaison, Project, Material Review MRB, develop new
shop plans, Configuration Management, I & R planning, processing outside production plans, producibility
development plans, modification KC135 re-engine CFM56 gas turbine engines Corrective Action accept/reject for
various shop problems for model 777 GE struts and nacelles, model 737 & 757 struts process documentation, 5S
and Kaizen principles for lean manufacturing, analytical labor efficiencies, work cells. PP&C manage military
program schedules with Secret Clearance, aircraft, missiles, rockets, weapons. Reduce engineering change
orders, reworks. Lean manufacturing using Six Sigma to attacks our inefficiencies – wastes by defects, non-value-
added flow of information or materials, data storage, stacks of inventory, overproduction and extra processing.
Learjet Corp., Wichita, KS. 6/1975 – 11/1978 Tool and Production Planner initiate on-line planning and tooling
orders. My duties to develop, maintain the planning for detail fabrication, assembly, installation plans. Lead Wing
Planner on the new aircraft programs first Learjet models with winglets to composite fiberglass lay-up details,
maintain production configuration establish functional test and using my problem-solving skills to determine and
implement practical solutions to improve the quality of world class aircraft with facts and available information to
develop logical assumptions and discriminate between important details in getting the projects completed in a
timely manner. My duties expedite material and parts needed to support manufacturing team with 5S & Kaizen.
Studies performance and troubles in existing tools and equipment
Military: U.S. Army - Infantry, Honorable Discharge with the Army Commendation Medal, CIB (Combat Infantry
Badge), National Defense Medial Vietnam, Second Tet Defense, Expert Medial qualify small weapons, APC M11.
Education: Wichita University - Wichita, Ks. – Business Administration in Marketing & Computer Science.
ICS Scranton, Pa. - Civil Engineering and Land Surveying.