N/C Machine Programs
Identified and provided a corrected standard practice for the multiple axis solution of the pogo skin machine. Errors occurred between the probing and drilling routines that didn't exist in the virtual checks, and were caused by the offset in C-axis 0 to 180-degree head position. By limiting the rotation of the 'C' axis in the APT Programs to 1st and 4th quadrants in both programs, the discrepancy was eliminated. [4-6-98]
Conceived and wrote the Drivmatic Plot routine used in all MCDs on the Drivmatic. This graphically displays the location of fasteners with restart positions throughout the NC program and aids the operators in correctly identifying the area of a program to fasten a particular area. [7-4-03]
Developed the technique and wrote the program to allow for segmented programming to overcome CADRA's size limitations of NC programs. This program recombines section 3 data for a single post processed MCD to the machine. [10-7-99]
Wrote a CATIA based system that used annotated data to produce an NC Program and then created a post processor to function with the Electro-Impact machine. Used on 3000+ stringer programs.
Conceived and wrote Knowledge Based Programming System for NC Programming (KBNC) for Torres Stringer Driller, Drivmatic Riveters, and Syn-Aps AutoRiveter. KBNC standardized all programs in Prep and Programming for the NCL system. KBNC made the preparing of programs a simple selection of data into specified groups. A C program then takes the data and analyzes it for use, sorts correct portions, and writes NCL style APT programs. The work of the programmer is to optimize the program where unique programming issues are found. The largest savings comes from the vastly reduced training time. Where it historically took 3 months to train, now most programmers are fully trained in 2 weeks. [Estimated 35,000 hours saved on 747-8F alone] [12-31-08]
N/C Machine Investigations
Identified the problem and redesigned the holding fixture for Clips on the Torres Stringer Driller Machine. The holder was positioned with two Cones and held on a rod; the new design used Diamond and Round Pins, a planar surface and a square locating surface. This improved the Clip locations from a .23 Cpk to a 1.4 Cpk.
Identified the problem and redesigned the clamping mechanism for the Torres Stringer Driller Machine. The original clamp was a sphere that provided no force against the stringer sidewalls. The redesign was a set of parallel nylon rods the spread when clamping, thereby forcing the centralizing of the Stringer during clamping.

NC Estimates and Work
C-17: Estimated, tracked and lead a team of MEs & NC Programmers on a 98 skin panel package. We predicted and obtained Zero Scrap and two minor reworks of NC Programs. All non-recurring work was accomplished on time (to a compressed schedule) and under budget.
Estimated SOW and prepared scheduled for all Plant 1 work on the 910K version of the 747-400.
Envisioned, designed and wrote Multi-Compare, which identified incongruent fastener location problems on released models. Multi-Compare can be used to check old to new, adjoining details and assemblies, probe data to NC Program to Engineering. Multi-Compare is a "Swiss Army Knife" for investigations of fastener congruency. Multi-Compare also identifies drain hole proximity problems on Stringer Models. This program has been used to identify approximately 10,000 errors significant enough to have almost 1,000 DCNs issued. Multi-Compare has been submitted for patent consideration at Vought Aircraft.
Compare - Internal QA to NC Validation Routine
Envisioned and developed a computer based virtual verification, validation routine for each numerically controlled machine tool. Compare interrogates NC and QA files prior to forwarding data to the respective machine. This is a virtual part try-out, eliminating a physical part tryout requirement. These programs have become an integral part of the very low scrap rate (99.65% FAI Acceptance as of 2007) on the Pogo Trim and Drill Machine.
Established the control of Labels for QA identifiers, now used by all downstream analysis. Standardizing the identifiers has clarified the warehousing of Inspection process results.
Developed auto-conversion routines for QA data to NC programs. Reducing an 8 - 16 hour job to a one-half hour job on every tool order.
Designed and wrote Drivmatic Compare Program that overlays Drivmatic, Stringer Driller, and Pogo NC Programs to assure proper synchronization, precise alignment, and eliminate redundant hole entry. [12-01-02]
Standardized the method of inspection of Skin Panels on the Pogo Trim and Drill Machine

CATIA to CADRA conversion
Developed the procedures for making CATIA data quickly and accurately available to CADRA.
Wrote the programs to convert CATIA datasets to CADRA code saving 16 - 24 hours per tool order. This process has dramatically improved reliability over previous CADRA buildset routines.
Laser Tracker Involvement
Designed the surface adjusters to control the surface contour of the panels at the Laser Tracker;
Designed a Clip Adjustment Tool that could relocate misaligned clips using Laser Tracker Report Data.
Designed a stringer centerline measurement tool for Laser Tracker.
Wrote software that interprets the Laser Tracker Report into readable files for Liaison Engineering and ME departments. Eliminates the manual discrepancy of hand-held readings and extrapolates to common locations for analysis.
Compared Laser Tracker data with Stringer Driller Program data to discover errors and initiated numerous investigations on the Stringer Driller Machine culminating in major repairs to the machine.
Developed the original "Panel Health" Report that provides an overview of the Laser Tracker Report.
Database for Laser Tracker Report Data -
Envisioned, conceived, prototyped, and developed the database with a linkage from Bill of Materials and CATIA datasets to provide accurate reporting with refurbished Laser Tracker Data.
Reduces 4 to 5 hours of search and computations per skin panel assembly for Quality, Liaison Engineering, MRB, and Manufacturing Engineering in Plant One.

Brötje AutoRiveter
Conceptualized, designed and programmed a data collection system (graphic prep) for the Plant Consolidation Bonnet Transfer to Dallas. This system uses CATIA NC-Mill to collect data and then processes the data for preparation of files required to produce FPDF files, and the reports to the database [Summer & Fall 2004]
Conceptualized, designed and programmed a system which uses data available from the graphic's prep process to calculate numerous requirements for the GSL file for the IGRIP program of the Brötje On-Line Programming System (BA-OLPS). This should save 6 to 8 hours of work for every iFrame program, and 20 hours of work for each iGantry program. [Summer & Fall 2004]
Design of a database for all fastener information collected during the graphic's prep process to drive planning and illustrated planning for the Brötje machines. [Dec '04]
Wrote the specifications for a release system for NC Programs for the Brötje machines
Wrote software for the analysis of start up Probe data from Pogo skin and Stringer Driller Machines. Investigating the Gage R&R capability of the Renishaw Probe and each machine respectively.
Designed a method to repair and rebuild Bond Jigs with accurate standardized locators. Original design used unique removable details on each BAJ, causing numerous long-term problems with lost locating details.
Envisioned and developed the concept of marking skin panels on the Pogo Trim and Drill Machine which accurately locates stringer centerlines, station locations, stay-outs and other useful information. This is also useful in re-positioning chem-milled skins accurately. Designed a specialized penholder to write with high positional accuracy for this project
Envisioned, and blocked out the idea for a Wave Cut Routine that could be added to Post Processors. This routine reduces cutter wear on thin parts, by bobbing the cutter up and down over the length of the part, thereby using the entire cutter's length rather than just a thin slice. This is estimated to save $50,000 per year in Milledgeville alone.[8/15/02]
Miscellaneous Software Development
Designed and wrote software to analyze Stretch Form Blocks for reversal. This exhaustive analysis provides a visual output of the analysis and can assist in determining the correct stretch direction for skins over a surface. Found that most of the 767 STFBs had reversal in the block as originally designed, program was extensively used to correct problems. Most of the 'difficult' blocks on 747 also have reversal. [12-5-02]. All current stretch form blocks are now analyzed through this system. [12-31-08]