Jose Maria Costa

Experience

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  ARCHO SOLUTIONS

  Jul 2003 - Nov 2007

  NC Programmer
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  Ambra Solutions

  Nov 2007 - Jan 2009

  Tool Designer
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  Zodiac Aerospace

  Feb 2008 - Aug 2008

  Aircraft Interior Design (Consultant via Ambra Solutions) at C&D Zodiac
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  Troya

  Jan 2009 - Apr 2012

  Manufacturing Analyst

  As a Manufacturing Analyst, my scope encompassed supports the evaluation of program and project requirements, develops moderately complex equipment and tooling concepts and designs solutions for the Production System;Estimates, plans, manages and executes the acquisition and modification of equipment and tooling;Develops and implements testing and acceptance to validate performance;Creates and maintains related documentation for equipment and tooling, develops preventative maintenance plans and trains personnel as needed;Develops and implements interim solutions for damaged and unsafe equipment and tooling;Main tools developed; mask for coordinated drilling, machining support devices, panel assembly jigs, forming molds for metal parts and jigs for joining segments.In MRO, I worked on the Lockheed Martin P3 Orion program (Brazilian Air Force) during the Rear wing revitalization due to corrosion. My scope of work was focused on manufacturing, where I performed activities such as interpreting technical manufacturing and assembly instructions for the wing and Wind Stub, developing disassembly and assembly plans, designing installation, drilling, and support tools. I also provided technical support for assembly of assemblies and sub-assemblies, performing initial installation, and training operators.All activities were based on Lean Manufacturing concepts to eliminate waste in all aspects of the manufacturing process and on Design for Manufacturability and Assembly (DFMA), focusing on product design to make it easier and more cost-effective to manufacture and assemble.The programs I worked on, in chronological order, were: Saab Gripen NG (working on the Rear Fuselage), Embraer E2 190 (working on the Central 2 and Wing Stub), Embraer KC390 (Forward Fuselage), and Lockheed Martin P3 Orion (in the wing revitalization and certification, providing MRO support).The most frequently used software included CATIA V5, VPM Dassault, TeamCenter, SAP, and PolyWorks. Show less

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  Saab

  Aug 2009 - Feb 2010

  Manufacturing Analyst (Consultant via Akaer) at Saab

  Technical support to the project group in methods and manufacturing process of machined parts for the Gripen NG fighter program.

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  Akaer

  Mar 2012 - Aug 2022

  Structural Design

  To analyze, interpret, and implement documents containing requirements and instructions written in English, in accordance with manufacturer standards and in compliance with aircraft certification regulations, such as FAR 25, FAR 145, and MIL-STD.During the PDR phases, I integrated multidisciplinary teams with the scope of interface between different development areas, representing the Structural Designers team. I was responsible for preparing and defining the CAD model (Coordinate Framework or Skeleton) as the engineering standard reference for lofting version control, defining the X, Y, and Z stations of frames, stringers, spars, and ribs, as well as refining the conceptual CAD models of the aircraft's primary structure and providing conceptual CAD models to the structural calculation team for preliminary load studies.In the CDR phases, I had the scope of refining CAD models according to preliminary reports from the structural calculation team, interacting with the primary parts manufacturing team to define manufacturing technologies, collaborating with the tooling team to identify and reserve interface points between segments, assemblies, sub-assemblies, and primary parts as per manufacturing requirements. Additionally, I provided technical support for manufacturing and assembly to the Designers team and collaborated with system teams, such as ECS Team, Fuel Systems Team, and Electrical Systems Team, for the definition and installation of support fixtures for these systems.In the FDR phases, as part of the structures team, my scope was to finalize the 3D/2D CAD models and, in other company programs, enrich the 3D concept with Model-Based Engineering (M.B.E.), where design requirements are directly communicated in the 3D model. My participation in this phase applied in two ways, both in execution and team coordination. Show less

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  Saab

  Nov 2019 - Mar 2020

  Manufacturing Analyst (Consultant via Akaer) at Saab

  NC Programmer:Define machining strategies and processes to manufacture metal parts in high-speed 5-axis machines, perform 3D simulation for process validation, impact analysis and in this scope, design tooling to support the machining process.

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  Airbus

  Sept 2022 - now

  Structural Design Engineer

  FAL and MRO:Focused on supporting the FAL (Final Assembly Line) and MRO (Maintenance, Repair, and Overhaul) based on the stringent standards established by FAR 27, FAR 29, and EASA Part 145. My expertise encompasses development, prototyping, installation, technical dispositions and validation of new STCs (Supplemental Type Certificate), as well as updating and revising engineering documents, all within regulatory guidelines;Determine technical repercussions after receiving Means of Compliance proposal documentation;Involvement with AS350 and H130 helicopters. Show less