David Rawley Email & Phone Number

Englewood, Co, Us

Englewood, Co, Us

Accountable for leading the strategic development and implementation of our production manufacturing plan. This plan emphasizes the paramount importance of quality and safety, ensuring alignment with our business objectives, proforma, and regulatory requirements while championing LEAN principles to foster a culture of continuous improvement.In coordination with the other executive leaders, I have developed and maintain a comprehensive company restart plan encompassing all aspects of the business during the restart of operations. This plan includes tasks and budgets and incorporates input from various teams such as Human Resources, Business Development, Operations, Engineering, Information Technology, and Finance. It enables us to accurately forecast the required funding to navigate the certification process and transition into the high-rate production of a two-seat all-electric basic training aircraft, as well as its four-seat counterpart.Collaborated with the executive team to prepare and present due diligence materials for Series B and C funding rounds in my areas of responsibility, including Supply Chain, Quality, and Manufacturing.

Englewood, Co, Us

I spearheaded the development of Bye Aerospace's operations team, with a focus on Manufacturing and Quality. My responsibilities included overseeing the entire operations lifecycle of the eF2, an all-electric, composite-structured, 2-seat trainer aircraft, from initial manufacturing to securing FAA Part 23 Amendment 64 Certification, Production Certification, and enabling mass production. I assembled a team of top-tier industry professionals capable of designing and implementing end-to-end production processes, Quality Management and Control, Manufacturing Engineering, supplier selection and management, DFMA, Manufacturing, and facility setup. I introduced standardized checklists and requirements for Design for Manufacturability and Assembly (DFMA), ensuring early assessments of product manufacturability during the design phase. Additionally, I managed and mentored a diverse cross-functional team in meticulously planning and establishing BYE Operations and procedures. This encompassed tasks such as supplier selection, DFMA, Manufacturing Plan development, EBOM and MBOM creation, and seamless documentation and communication through proprietary Pre-production Planning IP. As a member of the executive leadership team, I reported directly to the CEO, providing valuable insights on crucial key performance indicators, including planning status, budget, schedule projections, supplier updates, and product development progress.

Englewood, Co, Us

Responsible for enhancing the manufacturability of the eFlyer 2, and building a foundation for manufacturing engineering and production as a whole for the organization. This involved conducting meticulous Design for Manufacturability and Assembly (DFMA) assessments, collaborating closely with suppliers to communicate their capabilities to the Design Engineering team. Through these efforts, we achieved significant enhancements in part manufacturability within our supply base. To streamline our design evaluation process, I introduced proprietary intellectual property and supervised the utilization of design checklists, fostering a comprehensive approach to design assessment. Additionally began to revise, review and release of manufacturing, quality, and engineering processes, ensuring their alignment with our production objectives and planned capabilities. I developed annual budgets and schedules for the Manufacturing Engineering team, including forecasting capital expenditures. To enhance workflow efficiency and ensure the alignment of our efforts with manufacturing build plans, I established and communicated critical need dates to various departments, including Supply Chain, Engineering, Quality, Manufacturing, and Manufacturing Engineering via the proprietary IP set in place. This approach fostered a cohesive and coordinated effort to successfully achieve our production goals. My commitment to cross-organizational communication played a pivotal role in promoting collaboration across all teams. This led to improved clarity and definition of composite and mechanical design, Engineering Bill of Materials (EBOM), and Manufacturing Bill of Materials (MBOM) status. It also facilitated a more transparent presentation and refinement of the manufacturing flow for aircraft and sub-assemblies, and the total cost of production for the aircraft.

Englewood, Colorado, Us

Responsible for the overall build of the XB-1 experimental FWD Fuselage, Wing Spars, Horizontal Tail and development of thin facesheet cored laminate processes for use in the Vertical Tail and Inlets. Developed and documented the composite manufacturing processes with our material suppliers and contract M&P. Conducted composite supplier management and scheduling (on site and remote). Developed and executed manufacturing plans and schedules for detail fabrication and structural assembly. Conducted over 90% of detail and assembly inspections on the fuselage. Developed work instructions and mentored new ME’s on WI creation, fabrication techniques, and Boom processes. Supported, generated, and approved CPD and Fibersim data sets as required including mentoring of the various engineering teams in creating the data sets (in house, suppliers and contractors). Design for Manufacture and Assembly (DFMA) with in house and supplier engineering for tooling and drawings, with responsibility for approval on 78% of all composite parts. Procurement and set up of mechanical property testing equipment (MTS), detail drawings, and specimen fabrication and test execution of initial in house mechanical testing (lamina, laminate, and bonded specimen). Qualification and training for lamination and bond for both in house technicians and supplier organizations (engineering, technicians and quality departments). Supported facility layout and fit out for composite assembly. Successfully managed the fabrication and assembly of the BOOM XB-1’s 45 foot mostly composite fwd fuselage from initial design and tooling through final assembly and partial integration.

Zurich, Zurich, Ch

Initially brought on to simply create work instructions for detail composite part fabrication, I coordinated with GA’s New Product Integration and Manufacturing teams to standardize the detail part work instruction vernacular, format and repeatability as several contractors were brought in to produce them. This work includes the authoring and illustration of work instructions for primary and secondary composite details and assemblies. I also trained other contractors and generated the supporting documentation for the preparation of Creo Parametric design files for use in Fibersim. Generating a single file incorporating the clean OML and Over Core surfaces, each containing inter tool coordination features, EOP, MEOP, Direction and Origin features, core and FA boundaries as well as any localized reinforcement boundaries and ply drop offs from dumb solids to facilitate the use of limited NX and Fibersim licenses and team members, optimizing their time. In addition to ongoing Detail part work instruction creation, I was tasked with assisting in the documentation and transference of build process, techniques, materials, sequence, and assembly requirements for detail parts and sub-assemblies; via direct communication, CAD modeling, process mapping, and formal requirements documents from the offsite R&D facility to the Production facility. Work includes condition of supply documentation including CAD, work flow and tooling validation. Articles include Wing and Fuselage main structural assemblies and constituent metallic, printed, and composite detail parts, supporting the lead manufacturing engineers for each assembly.

Managing the overall engineering team for parts and ITAR materials, our team has streamlined the parts quote process from 6-10 week turn times to typically <2 weeks, while increasing the conversion of quotes to contracts from 10% FY15 to 26% FY16 and 44% as of Q2FY17. The team has decreased our response time to customer service and MRB to <24hr, and often <1hr while utilizing fewer staff. We were responsible for increasing the overall parts Sales Value and NRE by over 200% from FY16 to Q2FY17 through a focus on accurate, inclusive, targeted and timely quotes, while ensuring that the Design, Test, Build (Prototype/Limited Production/Soft Tooling) strengths of our team were capitalized upon and communicated to customers. Our success in this area was demonstrated by the repeat customers, and referrals our group received. My team created and implemented process flows, standard work instructions, and standard templates to improve consistency, accuracy, and throughput of common tasks. I ensured that our team was trained in and utilized RCCA and A3 problem solving techniques to course correct various problem projects and successfully manage projects through to on time completion while minimizing repeat non-conformances. Representing the company as program manager on part and material projects, I developed project lifecycle schedules from quote to delivery; tracked, reported and reviewed project status with our customers, internal and external, and coordinated with internal organizations in the successful implementation of project schedules, including design reviews, engineering and production milestones, and pre-delivery reviews. I was responsible for and ensured compliance to our engineering processes for AS9100 and NADCAP, as well as review and engineering approval of other company documentation and quality documents.

Mojave, Ca, Us

Responsible for the overall build of SS2 and WK2 Spars, SS2 Feather Assembly (empennage/horizontal tail), and WK2 Empennage Assemblies, including tooling and detail parts. Review and approve Engineering definition and process specifications, author and release tooling definition and work instructions to the shop floor and suppliers. Created standards for work instruction language. Coordinated DE’s, ME’s, QE’s and Production with Planning to document the Integrated Master Schedule in line with the proposed build of SS2. Constantly mentoring, training, and learning with new hire ME's, my peers, and others around the company. Defined and qualified our Equipment and work centers for production. Utilized Lean RCCA processes and A3 problem solving to define, correct and communicate solutions to the supplier production team, while on site at a pultrusion supplier, during our 11,000+’ production run for two vehicles. Ensuring the quality fabrication of materials required for the production of WK2 that was previously unachievable. Documented and defined standards for work instructions, inspection points, cure profiles, drawing reviews and automated progress reporting through our PLM and ERP systems tied to IMS and shop floor reporting of earned value and status. Lead several Kaizen workshops, and drive RCCA efforts to effect lasting resolution. Upgraded our curing oven to a higher capacity of part monitoring and improved control software. Created Visual standards where useful, and successfully derived consensus among ME’s regarding process definition. Defined and fabricated many NDT Standards for the quality department to refine their equipment and processes. Defined and assembled process monitoring equipment for use on the shop floor, capturing in a redundant fashion process and environmental data in a digital and user friendly format.

Mojave, Ca, Us

Establish the manufacturing process flow and documentation for building an all carbon aircraft, as well as an all carbon spaceship in an effort to setup production operations. Define what production equipment, tools, systems, and materials will be required in order to create an efficient, organized, and lean factory. Oversee the structural manufacturing and assembly operations of the vehicles and work on process improvement and production optimization using lean processes and tools.

Dorval, Québec, Oo

Interiors Integrated Product Development TeamIPDT Methods representative responsibilities, Author Methods Documentation (Manufacturing Requirements, Condition of Supply, Manufacturing plan documentation, and supplier Manufacturing plan review, on doc dates) and participate in supplier selections for the Learjet 85 Interiors. Definition and documentation of supplier Requirements, Definition and documentation of Legacy Lessons Learned, Lead Shingijutsu Kaizen Activities including legacy and IPDT members, definition and documentation of work cell layout, definition and documentation of standard work, preparation of manufacturing sequence and process, develop BOM and kitting requirements, and act as liaison between engineering design, suppliers, final assembly line Interiors Installation.Composite Technology TeamObjective: Plan for and execute the successful transfer of technology and tribal knowledge from Germany to locations in Mexico and the US. The team was responsible for approval of data sets for produceability, outlining Condition of Supply, Approval of Supplier Manufacturing Plans, specification of tooling requirements, identification and coordination of interface points, definition and documentation of work cell layout, definition and documentation of standard work, prepare manufacturing manuals, develop BOM and kitting requirements, and act as liaison between engineering design (Germany), suppliers (Global), final assembly (USA), and manufacturing (Germany/Mexico). Define and Document (Process Mapping and other) the Composite Materials, Manufacturing Techniques, Tooling, Equipment and Processes utilized in the manufacture of the all composite Learjet 85 in the transition between GROB and BA/LJ Design activities. Assist in the Jumpstart of BA/LJ/MMC Design activities and Facilities Preparation in Montreal QC, after the unfortunate insolvency of our partner GROB Aerospace.

Mexico Manufacturing Team Lead: Learjet 85 Wing, Horizontal, and Flight Control StructuresResponsible for Interview, Selection, Management, Coordination and Composite Consulting for twelve Manufacturing, and Methods Engineers in Montreal QC, and Mentoring of Mexico Team Manufacturing Engineer in Canada and Mexico. Our Team participated as part of the Integrated Product Development Team, and were responsible for Development of Preproduction Planning System, Material and Process selection, Interface Control and Management, Tooling Development and Definition, Facility Development and Layout, Design Development (DFMA through IPDT), Manufacturing Bill of Material, Monthly Reporting and Program Reviews, Manufacturing Plan Development, Component Outsourcing selection, Supplier Selection, Manufacturing Requirement Documents (both LJ FAL and MMC Subs), Condition of Supply (both LJ FAL and MMC Subs), Definition and Documentation of Standard Work, Definition and Documentation of Work Centers Cells and Jobs, Definition of Kitting requirements by Job, Cost Estimation and Roll up, Evaluation and acceptance of Detail Assembly and Installation Engineering and Drawing Signoff for JCDP JDP and Detail Design, Test article Development Analysis Specification and Manufacture, Validation Article development and specification, Full Scale Mockup, and Planning for the Manufacture of these structures in Mexico and Belfast. Successfully took the team from a single source GROB Design (wet lay) through to a Multinational integrated Bombardier Design (Prepreg, RTI, RTM, Composite/Metallic Hybrid), ready for Detail Design, Manufacture of tooling, and Start of Test Component Manufacture in Mexico 2 years prior to the original plan.

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Orchestrated the overall facility focus, coordinating the individual manufacturing cells, Production Control, Logistics, Purchasing, and Planning aimed at a just-in-time value stream, utilizing 2 bin stock, kitting, and kanban cards. Created a multi-level plant schedule updated via data from the MRP and supervisor input. Conducted kaizen activities with engineering to eliminate/minimize non-conformance occurrences, improve production flows and reduce scrap. Conducted initial kaikaku event driving towards single piece flow. Assessed bill of material contents, workflow structure, facility layout, work content planning, time standards, performance metrics, balanced cycle times, and evaluated additional manufacturing requirements, such as tooling and technology improvements to ensure quality and repeatability. Completed process map of design used in the identification and implementation of Lean Manufacturing opportunities.

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Trained new manufacturing team, geared toward streamlining manufacturability: emphasizing efficiency, proper technique, and attention to quality. Increased group efficacy with workflow and customer need analysis and improvements therein. Authored a comprehensive facility emergency action manual. Conducted internal audits of various groups and procedures to verify that written policy covered key manufacturing traceability requirements set by the FAA in preparation for production certificate at Adam Aircraft. Published a summary of findings and suggested improvements to management.

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Successfully managed internal and FAA Static Testing for the Adam A500 program in Pueblo. Consistently exceeded aggressive corporate goals through effective leadership, teamwork, and coordination of internal and external groups. Responsibilities included: Supervising teams of up to 20 on three separate test rigs, coordinating manufacture of articles, scheduling, set-up, conformity, maintenance, article repair, problem solving opportunities, as well as administration and documentation of all required full scale structural testing. Signed 8130-9’s for FAA testing, and coordinated with engineering and manufacturing. Designed and implemented Safety policy and procedures for Static Test environment.

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Managed a team of 10-14 in the airframe assembly of SN001. Coordinated with engineering to define and document Adam processes and specifications. Developed the initial patterns for Pre-preg laminations and core. Selected as an advance team member sent to Pueblo to oversee the opening of operations in Pueblo, Colorado. Managed construction of plant set-up/layout, clean room layout, and oven set-up. Additionally responsible for the leadership, training, and qualification of initial manufacturing team and environments at the Pueblo facility.

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Produced master tooling, production tooling, initial parts, assembly jigs, and sub-assemblies required for the initial concept and production run of the Adam A500. Qualified to instruct courses in drawing use, tooling, pre-preg and wet lay-up, oven operations, trim and drill, bonding, and repair (scarf and step, wet and pre-preg).

Managed multi-lingual teams up to 25 staff on multiple job sites across the Denver Metro area and North Dakota. Coordinated initial customer contact, estimation, scheduling, crew loading and planning, materials management, product delivery, and fleet maintenance. On-site management of: installers, quality, safety, security standards, progress reporting, final walk-through, and warranty work. Additional ownership duties included: financial recording, forecasting, budgeting, transactions, interviewing, hiring, performance assessments, corrective actions, mentoring, training, ordering and purchasing consumables, contract negotiation, and overall operations management.