Antonio Conversano, MBA

Experience

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  Leonardo

  Feb 2004 - Oct 2008

  Manufacturing Engineer - Aerostracture CoE (Helicopters Division)

  Hired to assist engineering team in evaluating Aero Structures manufacturing processes and product design, fabrication, and assembly methodologies to streamline production programs. Ensured all production processes met quality design requirements. Improved manufacturing efficiency by analyzing and planning work flows, space requirements, and equipment / floor layout. Prepared product and process reports.Key Contributions:♦ Hand-picked to participate in prestigious US Presidential Helicopter Program (AW VH71) development project. ♦ Provided critical information to support the manufacturing decision-making process by calculating production, labor, and material costs; reviewed production schedules; estimated future requirements. Show less

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  Danieli s.p.a.

  Nov 2008 - Jun 2009

  Senior Manufacturing Engineer

  Interfaced with internal stakeholders to define project scope, identify potential issues and material inadequacies and devise plan to correct any and all production issues. Remained up-to-date on shop floor production needs, worked with line managers to evaluate tools and interpret schematics / blue prints. Coordinated with other departments to compete work on time and to the highest quality standards.Key Contributions:♦ Validated, improved and corrected production/project TA by rerouting the activities to different work centers.♦ Reduced per part/assembly costs by 7% by utilizing historical manufacturing data to implement line changes. Show less

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  Cozzarin

  Jul 2009 - Oct 2010

  Project Engineer

  Customer facing role, providing cost, feasibility analysis and schedule for primary and secondary wooden structures (roofing & housing) , developed 3D modelling and and CNC programs to machine structural elements, coordinated and overseen crews during project execution.

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  Leonardo

  Jun 2011 - Sept 2017

  Provided high-level supervisory support in directing and managing daily research and development activities for AW609 product line. Led team of ME Managers and ME Supervisors in coordinating the tooling and process improvement programs, and implementing key testing and assembly methodologies to ensure quality production. Served as liaison to Manufacturing/Industrial Engineering teams, Material Management, Operation Management, Production Control, QC/QA, Program Management and CPE office to ensure achievement of cost/schedule goals. Administered budgets and CAPEX / equipment purchases. Assigned work schedules, monitored job progress, tracked completion and reported achieved project benchmarks to the Senior Management & Executives.Key Contributions:• Established Experimental Operations Manufacturing Engineering processes in pure production facility.• Leveraged “hands-on” management style in leading and directing floor technicians / supervisors of two full production crews to implement high quality production programs and complete improvement projects on time.• Reduced AW609 TiltRotor product development Time Assigned (TA) by 20%, a savings of 8K man-hours.• Played key role in reducing standard training time to transition a Junior ME from Production to Experimental Operations from three to six months down to only two weeks, thus realizing immediate operational efficiencies.• Coordinated and managed Test facility in Michigan with the Italian based team, ensured daily availability of the aircraft for flight test activities. Show less Hired to assist in the development and creation of new aircraft prototype product, including overseeing and managing Testing Facility plant at the Arlington, Texas. Established all inventory control processes to ensure timely international transfer of internal company assets to maintain production/testing schedules. Coordinated with floor supervisors, managers, and team members to establish manufacturing process and administer unit budget and CAPEX. Reported to Senior Management and Executives on achieved project milestones. Key Contributions:♦ Drove process to implement visual factory (Poka Yoke) and 5S improvements across entire production process. ♦ Credited for reducing aircraft maintenance downtime by 30% as compared to the Italian based crew.♦ Reviewed, optimized and documented assembly work instructions and production sequencing activities to reduce costs and improve the JIT process, ensuring accuracy and prompt filing of aircraft build records.♦ Planned and executed deployment of prototype aircraft in less than week from Arlington TX to Anaheim CA. o Project included configuring aircraft, upgrading flight control software, completing new paint scheme and receiving release of airworthiness certificate from the FAA. o Program received major public exposure that led to the possibility of guest pilots flying the prototype. ♦ Played key role in ensuring facility operations met OSHA regulations. Show less

  • Lead, ExpOps Manufacturing Engineering - Project Lead (Helicopter DIvision)

    Jul 2015 - Sept 2017

  • SENIOR MANUFACTURING ENGINEER – EXP. OPS. / EXP. OPS. LIAISON / FAL (Helicopter DIvision)

    Jun 2011 - Jul 2015
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  Independent Consultant

  Nov 2017 - Apr 2019

  Business Management Consultant

  Support and lead small and medium Aerospace and Manufacturing businesses, established and start-up, in the following areas:- Definition of internal manufacturing processes and facility lay out (Lean / 5S/ Visual Factory & Poka yoke /6S);- Definition of inter departmental processes, rule of engagement, departments outputs and KPIs;- Change Management and training path development;- Development of Inspection plans for First Article Inspections and Conformity Inspection to assure Design and Quality requirements are met;- Capital Expenditure definition and justification;- Business Development. Member of Guidepoint Global and MentorSelector Show less

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  GKN Aerospace

  Apr 2019 - Sept 2019

  Chief Manufacturing Engineer

  Technical leader for the Mfg Eng department, responsible for the manufacturing definition and ME related activities within the program / value stream through its life cycle. Leads multi-functional ME team deployed into the program / values stream and acts as the primary representative for ME at all program / technical reviews & externally (with customer & suppliers). Ensure the manufacturing system meets stakeholder requirements including; technical compliance; adherence to ME processes and standards and compliance business case (including Q/D/C).Responsabilities: • Delivery of a manufacturing system that fulfills all stakeholder requirements including: Quality, Health & Safety, design, producibility, business case.• Responsible for the manufacturing process definition and ME related activities within the value streams and throughout the program lifecycle, including factory layout.• Represent M.E. at internal program / technical reviews and with Customer & suppliers, ensuring that the manufacturing definition meets stakeholder requirements.• Drives concurrent engineering and participates in design reviews to meet business case targets, including DFM.• Product development: Selection of capable manufacturing processes, Validating the capability of the process and/or equipment, Introduction of new technology in line with the Program / Value Stream requirements and Supporting the Make v Buy & subsequent supplier selection process• Ensure adherence to all applicable Quality processes and procedures including regulatory laws and guidelines, Customer requirements and Export Control and ITAR requirements• Daily team management: Ensuring that safe working practices are maintained at all times, Allocation of task in line with the agreed schedule / budget and ensuring that all M.E. related reviews are completed to schedule and that the inputs / outputs are managed to the defined process• Support the Design Chief Engineers on their technical reviews as required Show less

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  Bell Flight

  Sept 2019 - now

  Project Manager and Control Account Manager for the FLRAA's Build Team during Weapon System Development Contract, trough Milestone B award and entry into Engineering and Manufacturing Development Contract. Successfully defended the developed and managed Integrated Master Schedule during Integrated Baseline Review. Increased sphere of responsibility from circa 20 Control Accounts and ~$96MM of budget (NRE) of the WSDC to over 200 CAs and over >$600MM (RE+NRE) for the EMD phase. Mentored other CAMs and liaised across other IPTs to properly identify handover points for horizontal integration to/from Build Team efforts to ensure accurate forecasting. Show less Provided high-level Project Management (cost, schedule, efficiency) and Manufacturing Engineering guidance in re activating the production line of a high complexity, high dollar value (>400K USD per unit) critical subcomponent, managing relevant KPIs. Led multi-functional personnel in daily operations. Negotiated with Senior Site Leadership shop priorities to meet contractual milestones. Guided design changes. Leading international and multidiscipline team in the development of a multi-million dollars Product Support Agreement. Key Contributions:• Reduced turnaround time of critical subcomponent from 42 days to 18 by the 6th unit without utilization of overtime• Supported multi-disciplinary team in the reduction of scrap rate from 60% to 15% by the 18th unit of a critical component• Leveraged “hands-on” management style in the cross-training initiatives with Process Engineering, Quality and Engineering to ensure full production capability on 3 shifts could be achieved.• Reduced backlog of Repair and Retrofit assets aging up to 4 years to schedule within 10 months• Led diverse team in the development of a Product Support Agreement Proposal where the Company act as Supplier instead of OEM• Led development of MSG-3, FRACAS and FMECA analysis for blades and yokes and successfully represented the Company during MRB review Board with Customer and Certifying Authority (FAA, EASA) Show less

  • Product Manager, FLRAA Build Team

    Jan 2025 - now

  • Project Manager & CAM - V280 Program Controls

    Sept 2022 - Feb 2025

  • Sr Project Engineer, Manufacturing

    Sept 2019 - Sept 2022