Lloyd A. Schaefer
Professional Engineer: ASNT Level III, ASQ/CQE, DGZfP, PMI-PMP
e-mail: schaefer@pnde.net
SUMMARY:
EXPERIENCE:
1995-1997, 2002-Present: Honeywell – Global Repair Development – Principal Engineer
Lead engineer for an Integrated Product Team which developed & prototyped SAM, a structural anomaly mapping and characterization system for airframe structures and wiring | |
Process leader for Reverse Engineering Globalization – Established design resource COE in India | |
Review OEM and 3rd party manufacturing processes (ORIs) for quality topics on developed repairs | |
Monitor global RDE activities to assure technical accuracy. Emphasis on NDE, rotating components and processes. Lean optimize design requirements. | |
Investigate new repair technologies for turbine cold section repairs; Adaptive machining and 3D adaptive laser welding for blisks and impellers. | |
Lead development of Technology STRAP for the Aftermarket using Vision Strategist. | |
Investigate NDE revealed anomalies in OEM and 3rd party repairs | |
Investigate and develop new NDE technologies, via IR&D and cooperative developments with Universities and Govt. R&D | |
Conduct NDE POD assessments for developed NDE. Support validation efforts with FAA, MIL | |
Perform Root Cause and Corrective action processes for development activities, e.g. SAM | |
Member of ISU-CNDE Industrial Advisory Board & Engine Titanium Consortium
(POD and In-Service Inspection Development Team) |
Accomplishments/Recognition:
Technical Excellence recognition for Blisk Impeller repair technology development | |
Program award for SAM System development and integration – Patent disclosure filed | |
Six Sigma Plus DFSS & Green Belt Certification – (Impeller/Blisk Weld Development) | |
Quest for Excellence Award for Globalization of Reverse Engineering processes | |
LabView Developers Training completed | |
Advanced Eddy Current Technologies Seminar completed | |
Project Management Training completed - PMP | |
Aviation Week and Space Technology recognized the SAM development as innovation of the year | |
Directors award for excellence in development of Eddy Current technology for the 731 fan disk program |
2000 – 2002: SIEMENS PG Berlin Germany – Product/Process Engineer, Sourcing Europe
Leader for turbine blades and vanes Process Improvement Team | |
Qualify new casting, coating, machining and performance test processes | |
Monitor supplier quality, maintaining scorecards for quality and on time performance | |
Support special process substantiation and conduct First Articles | |
Survey new and existing suppliers for quality system conformance | |
Conduct corrective action investigations in response to adverse performance trends | |
Developed quality requirements for new, Siemens-Westinghouse Advanced turbine design practice | |
Evaluate NDE results and procedures for turbine blade & vane quality; Eddy Curent, Thermography, Radiography and Ultrasonic | |
Provide native speaker (English) liaison services between various elements of Siemens-Westinghouse and the global supply chain |
Accomplishments/Recognition:
Reduced coating supplier deficiencies by > 30% while improving on-time performance to > 95% | |
Leadership award for Quality/Specifications contributions to a new, joint Siemens/Westinghouse design philosophy for the next generation industrial gas turbine | |
Six Sigma Greenbelt project: Blade & Vane cold flow test optimization | |
Attained German fluency, and responsibility for Swiss supply chain (blade coating technologies) |
2000: SAUDI ARAMCO, Dhahran, Saudi Arabia - AlHoty – NDE Level III Specialist
Performed Level III functions for various in Kingdom oil and gas projects. | |
Review project NDE results (radiographic film interpretation, FPI, Mag Particle) and monitor quality performance | |
Conduct project quality systems assessments at the Hawiyah Gas Plant development | |
Conduct audits of in and out of Kingdom supplier quality procedures and performance | |
Review NDE specifications |
Accomplishments/Recognition:
Attained Aramco certifications for NDE methods, and Radiation safety practices for using Isotopes | |
Wrote software to link digitized radiography systems across Kingdom networks |
1987-1995, 1997-2000: BOEING – PRINCIPAL ENGINEER
BCAG – Rocketdyne: Airframe Structures, Rocket Turbomachinery, and Electric Power Systems
Program Quality Manager for the 5 major Space Station Electric Power System NDE Subcontractors | |
Developed, documented and implemented quality inspection processes, including NDE, for Space Station Electric Power System, Shuttle Main Engine and Expendable Launch Vehicle turbine engines | |
Quality representative on Integrated Product Teams (IPT) for the design of new engines (X-33 Linear Aerospike, Adv. Launch System, National Launch System) | |
Investigated, developed and implemented novel NDE technologies; automated Eddy Current, Ultrasonic, Laser Shearography, Thermography and Computed Tomography, for Fracture Critical applications and flight hardware anomaly investigations | |
Audited and assessed quality performance of manufacturing & NDE processes on production, test and flight hardware throughout the supply chain and at customer operational sites | |
Wrote and implemented procedures and techniques for developed NDE inspections | |
Performed first article inspections on castings, forgings, brazed assemblies and welded structures | |
Developed and implemented inspections for composites used on the Space Station ORU structural enclosures | |
Functioned as liaison to structures and lifing disciplines on issues of fracture control from the Quality Organization |
Accomplishments/Recognition:
Engineer of the Year recognition in 1994 | |
5 Invention disclosures filed with NASA (NASA TU) | |
2 Leadership awards for excellence in management of cross functional Mfg & Eng teams to improve quality and develop essential NDE technologies for assurance of Space Station flight hardware | |
IPT Team Award for On Time and Technical success for the X-33 Combustion Devices program | |
NASA Silver Snoopy Award for assurance of Quality on the SSME program. Awarded to less than 1% of NASA program workers | |
R&D 100 nomination for inspection system developments for Space Station Electric Power | |
Promoted to Engineer Specialist | |
Published Weld & Microelectronics Quality Inspection section in ASNT Visual Testing Handbook, 8th Edition |
1984 - 1987: NORTHROP ELECTRONICS - ENGINEER, METALLURGICAL ENGINEERING
Provided materials and process engineering support for a variety of missile/aero guidance systems, Turbine Engine and Airframe monitoring systems including their; mechanical structures, heat exchanger systems, support electronics systems & components. |
Accomplishments/Recognition:
Received TAP (Target Accountability Program) performance recognition for work in development of dimensionally stable investment Aluminum casting alloy, and radiographic test methods for investment castings, microelectronics DPA and printed wiring board analysis | |
Techniques for PWB and Microelectronics DPA recognized as "best in class" by DPA Labs Inc. | |
Visual and metallographic practices for Electronics and soldering analyses adopted in ASNT Vol. 8 on Visual and Optical Testing |
PUBLICATIONS and PRESENTATIONS:
INSITU Computed Tomographic Failure
Analysis of RVDT Thermistors
(L. Schaefer - NASA Tech Brief 1988)
Ultrasonic Inspection of turbine investment castings Using Flaw Classifier Logic (L. Schaefer, J. Willenberg - NASA Tech Brief 1989)
Laser Shearographic Inspection of Thrust Chamber Hot Gas Wall Bonding
(L. Schaefer - NASA Tech Brief 1990)
Eddy Current Flaw Discrimination In Pressure Vessels Using Pattern Recognition
(L. Schaefer, J. Willenberg - NASA Tech Brief 1992)
Computer Assisted Inspection for Welded Thin Wall Pressure Vessels
(L. Schaefer, G. Light, R. Tennis, J. Fisher - R&D Magazine - 1992)
AI for Bond Inspection - Signal to Noise Ratio Improvements
(L. Van Wyck, L. Schaefer, L. Rochester- Rockwell IR&D - 1992)
High Reliability Evaluation of Printed Wiring Boards by Radiography
(L. Schaefer - ASNT Conference proceedings - 1991)
Pre-Penetrant Surface Enhancement Techniques
(L. Schaefer - ASNT Conference proceedings - 1992)
Probabilistic NDE for Bonded Structures
(L. Schaefer - ASNT Conference proceedings. - 1992)
Developing Probabilistic NDE Solutions for the Space Station
(L. Schaefer, W. Nagel - ASQC Chapter presentation - 1993)
ASNT Visual Testing Handbook (Eighth Edition) – Visual & metallographic techniques for joining processes & microelectronics (L. Schaefer, et. al. Published September, 1993).
Quantifying Shearography for Fracture Critical ORU composite enclosures
(L. Schaefer - SPIE conference proceedings - 1995)
http://www.spie.org/search/spie_ab_search.htmlNDE Automation in the Inspection of Thin Wall Pressure Vessels
(L. Schaefer, M. Mitchell - QNDE conference proceedings - 1995)
Novel NDE methods for assessment of bonding in brazed anisotropic honeycomb structures
(L. Schaefer & Dr. G. Light - SAMPE proceedings – 1998)
http://www.olemiss.edu/depts/compmatl/lit/sampe2.htmlAging Aircraft Risk Based Inspection
(L. Schaefer, ASNT Seattle Section Presentation, 1999)
Process Targets and Metrics for NonDestructive Inspections
(L. Schaefer, ASQ Seattle Section Presentation, 2000)
Whole R Considerations for NDE in American Aerospace
(L. Schaefer, World Conference on NDT, Rome Italy, 2000)
http://www.aipnd.it/program/frid.htmDigital & Human FactorsTools for improving RT process reliability
(L. Schaefer, In-Kingdom NDE Technical Exchange Conference, 2000)
Creating POD Practically
L. Schaefer, R. Singh, European-American Reliability Workshop Tutorial, Berlin 2002
Structural Anomaly Mapping for Airframes: Data Acquisition/Detectability Testing
(Waled Hassan, Lloyd Schaefer, Tim Duffy, Johnathan Edwards, Dave MacEnany, Caroline Morel, Stu Rosenwasser, QNDE – Green Bay, Wisconsin 2003)
Ground Based Vehicle Health Monitoring for Lifecycle Cost Reduction
(L. Schaefer, SAE Aging Aircraft Conference, Montreal 2003)
EDUCATION AND CERTIFICATIONS:
MS Technology Management, UOP Distance Learning In progress, - ECD 12/06
BSc Cum Laude Industrial Technology, University of Southern Illinois
AAS Metallurgy, Milwaukee Area Technical College.
ASNT Level III - Certificate Number MM-982 (UT,RT,PT,ET,MT)
ASQ-Certified Quality Engineer (CQE)
ASQ-Certified Reliability Engineer (CRE) – 2005
AWS-CWI Examination April 2005
Boeing Structural Engineer Training, 1998
DFSS – Six Sigma Greenbelt certified, 2003
PMI-Project Management Professional (PMP) - 2005
PROFESSIONAL AFFILIATIONS:
American Society for Metals (AMS)
American Welding Society (AWS)
American Society for Quality (ASQ)
American Society for Non-Destructive Testing (ASNT)
DGZfP – German Society for Non-Destructive Testing
Project Management Institute – (PMI)
CONTINUING EDUCATION:
Computed Tomography, Theory and Operation – ASNT 1985
ISO9000 Auditing – AlliedSignal 1996
Quality Function Deployment & Taguci methods – Rockwell 1990
Digital Signal Processing - Iowa State University 1995
Boeing D1-9000 ISO Supplier Auditing Training 1998
Design To Cost – Boeing 1998
ANSI Dimensioning and Tolerancing – Boeing 1994
Aircraft Structural Engineers certification – Boeing 1999
Labview Developers Training 2003
Eddy Current advanced technology seminar 2003
Six Sigma Greenbelt training – 2001 (Siemens-Westinghouse)
Design for Six Sigma, Six Sigma Plus – 2002
FAA STC/PMA Validation Methods training – 2004 (Honeywell)
Managing Projects – 2004 RSI/George Washington University
Project Leadership, Management and Communications – 2004 RSI/George Washington University
MPC Maturity Path Planning – 2004 (Honeywell)
RCCA Process Training – 2004 (Honeywell)