Michael Schaaf Email & Phone Number

Atlanta, Georgia, Us

Winslow, Maine, Us

Responsible for developing manufacturing methods for assigned aerospace components. Create routers in ERP system and providing technical support to outside vendors.

Developed manufacturing process, including fixtures, for six rocket engine boost components.Process included Electro-Chemical Machining, turning, milling, and CMM inspection.Designed ECM tooling for use on six rocket engine boost pump components. Developed a five-step manufacturing process, including fixtures, for helicopter weapons pylons. Designed all milling fixtures and tombstones for a five pallet machine.Designed milling fixtures and tombstones for use on airliner flap assembly components.

Birmingham, West Midlands, Gb

Lead Engineering Department which consists of 8 Mfg. Engineers, 6 CAD Designers, 4 CNC Programmers, and 2 Engr. Technicians. Responsible for all process development, tool and fixture design, CNC programming, and Inspection Systems.Directed implementation of SPC in Blisk manufacturing value stream. Increased monthly deliveries by 100% while reducing non-conformances by 75%.Lead development of an adaptive grinding process for use in Blade manufacturing value stream. The new process reduces scrap and rework by 80%.Implemented new data collection and analysis tools to drive process improvements across all value streams. Process data for airfoil and flow path can now be gathered and analyzed in near real time.Completed GKN Leadership Training Course.

Birmingham, West Midlands, Gb

Developed manufacturing process for various gas turbine compressor blades. Process included Electro-Chemical Machining, creep feed grinding, and CMM inspection.Directed a cross-functional team to improve quality issues and eliminate delivery arrears for CFM56 Compressor Outlet Guide Vanes. Reduced non-conformances and rework by 75% and eliminated over $2,000,000 in delivery arrears.Reduced non-conformances and rework by 90% on F110 Compressor Outlet Guide Vanes by using SPC to make ECM cathode iterations. ECM cathodes are used to create final airfoil geometry.

Paris, Île-De-France, Fr

Developed prototype process for Air Conditioner evaporator assembly. Allowed prototype production to be re-located from Europe.Installed new evaporator assembly line capable of producing 500,000 units per year. Completed Process Flow, PFMEA, and Process Control Plan for this assembly line.Managed vendor design, construction, installation and start-up of new tooling for two evaporator assemblies using existing machines.

London, Gb

Developed plastic vacuum forming molds and specified new material for use in new exterior trim applications.Designed new vacuum forming mold to produce armored bulkhead door covers. Managed vendor design, construction, installation and start-up of new large cut-sheet vacuum forming machine.Developed armor location fixtures.Reduced manufacturing hours on armored Toyota Land Cruisers by 200 hours per vehicle.Created Manufacturing Planning for Toyota Land Cruiser production.Developed interior trim package for BAE Systems Severe Duty Truck.Re-designed armored bulkhead door assembly and saved $1500 per vehicle.

Essen, De

Led Cadillac CTS Front and Rear Coil-Over-Shock Module project. Created machine specification, directed vendor design, construction and installation of four machine production line.Created machine specification, managed vendor design, construction and installation of a low-volume flexible Coil-Over-Shock Module. Performed retrofit of an assembly line for production of Front and Rear Coil-Over-Shock Modules. Eliminated need for new equipment.Developed machine specification, managed vendor design, construction, and installation of assembly machine for Rear Shock Absorbers.Created specification for pick-and-place retrofit. Directed vendor design, construction, installation, and integration retrofit unit. Created common design with a newly purchased machine.Completed Process Flows, PFMEAs, and Process Control Plans.Led ongoing Six Sigma Green Belt Project to improve efficiency of Final Assembly machine.

Cincinnati, Ohio, Us

Installed $1,000,000 automation project on time and $50,000 under budget. Relocated an existing line and debugged both new and relocated machinery. Supervised vendor design and construction of the new equipment.Developed manufacturing standards and production reporting for utilization and efficiency on 17 major pieces of equipment.

Prepared piece price and tooling cost quotations for interior and under-hood components.Performed prototype development and production transition for engine cooling fans.Relocated quality containment operation from outside contractor. Prepared work instructions and supervised operators. Designed new one-piece flow layout and standardized work assignments to accommodate volume increases of 150 armrest assemblies per day.

Coordinated building of tooling and prototype parts for 10 automobile interior components. Planned timing of inventory bank, tooling changes, and component changes to complete multiple engineering changes. Led on-site customer support of engineering changes and quality concerns. Participated in Value Analysis with customer to achieve $800,000 per in cost savings.

Purchased assembly fixtures and developed standardized one-piece flow work processes for interior component assemblies to meet a takt time of 325 assemblies per day. Developed lean manufacturing work sequences, including quick-change procedures, to manufacture overhead consoles. Estimated piece price and tool costs for four programs totaling sales of $20,000,000. Prepared QS9000 submissions for 25 interior components.Established piece price and tooling costs for multiple trim assemblies with sales of $25,000,000. Developed one-piece flow work processes and assembly tooling for three manufacturing areas to meet a takt time requirement of 900 of each assembly per day. Supervised prototype part assembly and shipment. Reduced annual labor costs $150,000 by completing time studies to create balanced work.Established piece price and tooling costs for all new programs for the entire corporation. Supervised build of injection molds, CMM fixtures, and assembly fixtures for interior parts.Received Lean Manufacturing training (TPS) for production line development.