Charles Sunkes

Experience

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  US Army

  Jan 2006 - Jun 2013

  Aircraft Maintenance Technician/Supervisor

  Provided professional recommendations associated with maintaining the aircraft market value and upkeep related to asset management. Maintained technical proficiency and familiarity with regulatory requirements.•Performed inspections and repairs of aircraft and components following maintenance procedures, airworthiness directives, service bulletins, service letters, and applicable FAA regulations.•Ensured that all maintenance supporting documentation was executed in compliance with applicable FAA regulations, company policies and procedures, and applicable maintenance manuals, to include specific chapter references.•Assigned personnel to tasks commensurate with abilities and set daily objectives to be met. Demonstrated proper techniques to perform necessary work. Evaluated personnel to ascertain strengths, weaknesses, and worked to improve team members in needed areas.Select Accomplishments•Conducted emergency replacement load-out to replace two aircraft that had crashed overseas in a war zone. Prepared two helicopters as replacements, which were ready for shipment within eight hours, loaded onto a cargo aircraft, and flown from the U.S. to Afghanistan in support of forces in the field.•Regarded as a subject matter expert on assigned aircraft; routinely sought out by superiors, subordinates, peers for advice and mentoring. Show less

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  DynCorp International/AECOM

  Aug 2013 - Aug 2014

  Quality Assurance Specialist

  Inspected the work of multiple aviation maintenance technicians. Certified that the quality of work complied with the Federal Aviation Administration (FAA) and the manufacturer's specifications either before the release of an aircraft from the maintenance repair facility or after the completion of emergency repairs at a remote location.•Conducted aircraft inspections, including initial, in-process, visual, condition, accident damage, and final inspections as well as during maintenance operational checks.•Evaluated discrepancies and recommended proper courses of action; evaluated aircraft components and structures to determine serviceability. •Reviewed and interpreted new and existing technical publications applicable to inspection, modification, and maintenance of aircraft and equipment and resolved technical problems encountered. •Implemented directives, manufacturer service letters, bulletins, information notices, and technical publications to ensure verification of airworthiness of aircraft and that all entries were recorded in the logbook according to applicable technical manuals and procedures.•Maintained records of all precision measuring, balancing, and test equipment; ensured performance of all required calibration checks to keep the equipment in usable condition. Maintained regular contacts with FAA inspectors on issues relating to the operation of a certified repair station facility.Select Accomplishments•Initiated and reviewed quality, technical deficiency, and hazardous material reports for accuracy and clarity.•Informed that a helicopter was in a test flight without the necessary documentation. Notified Flight Operations to direct the aircraft to land immediately. The unchecked maintenance was corrected and the aircraft was allowed to resume its test flight several days later. If this unchecked maintenance had been ignored, an in-flight mechanical failure could have occurred, resulting in fatalities. Show less

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  KYOWA AMERICA CORPORATION

  Apr 2018 - Mar 2020

  Production Engineer

  Specified design of equipment/tools to assist in new and existing production processes as well as obtain quotes/bids for the construction of equipment to submit with recommendations. Recommended and implemented improvements to production processes, methods, and controls. Coordinated manufacturing launch for new or revised machined products.•Designed tooling and fixtures for use in the production and inspection of company products. Implemented statistical process control and conducted capability studies on critical processes.•Employed measurement tools to analyze work samples in developing standards for labor utilization. Estimated production times, staffing requirements, and related costs to provide information for management decisions.•Recommended methods for improving worker effectiveness, safety, quality, and cost reduction, including recommendations for restructuring job duties, reorganizing workflow consistent with demand flow technology, relocating workstations, and purchasing of equipment.Select Accomplishments•Designed and built a fully automated poke-yoke for Toyota to ensure operators installing tape pressed firmly on its edges to avoid peeling. The poke-yoke remained clamped for several seconds of firm pressure to ensure good adhesion, which resolved the quality deficiency and allowed production to resume after the system was adopted for three other stations. Show less

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  Boyd Corp

  Mar 2019 - Aug 2019

  Project Engineer

  Performed engineering design evaluations and worked to complete projects within budget and scheduling restraints. Co-designed manufacturing processes for new product development through cross-functional design teams. Established production processes and measurement parameters for new products.•Planned, scheduled, and coordinated departmental activities to fulfill sales orders and meet company goals/objectives and inventory requirements, which empowered delivery of the manufactured products to the client in a timely fashion.•Provided engineering coordination of new product development, to include new technology equipment investigation and evaluation of equipment capability.•Applied engineering knowledge to generate concepts and completed the product support design as well as work with the Production department in implementing new or revised product support designs.•Developed process routings and labor standards for use in proposal cost estimating and shop floor control scheduling requirements.•Developed and implemented production process layouts and manufacturability plans. Developed capital equipment specifications and supported the justification, installation, and start-up.Select Accomplishments•A customer discovered a new medical compound, specifically a silicone polymer, that could save lives. Worked with the customer and sales representative to design several prototypes to determine the feasibility of manufacturing a product that could deliver this new compound. After testing several prototypes to no avail, created a screened filter that allowed the polymer to remain adhered to the medical dressing for ready availability.•Inherited some faulty-processed jobs from a recently purchased company. Designed and tested a new tool to increase production while staying well within safety parameters. Within two months of test completion, all tools and machinery were refurbished and in use, which increased production by 100%. Show less

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  Honeywell

  Mar 2020 - May 2020

  Advanced Manufacturing Engineer

  Reviewed and interpreted product design drawings to develop work instructions and process procedures and enable operational personnel for production per design specifications. Analyzed operational data such as workforce utilization and facility layout to design workspace following lean manufacturing principles for maximum effectiveness of workers and equipment.•Supported the Management team by providing manufacturing engineering technical expertise and working collaboratively on processes. Provides the technical support to assemble aerospace pneumatic control components, including valves, starters, and actuators.•Worked with operators and technicians to improve operator instructions; tests and diagnoses mechanical components to determine the root cause of failure.•Evaluated standard parts and recommends disposition for current utilization, rework, or referral to Material Review Board.Select Accomplishments•Identified an issue with a component manufactured for the F-35 aircraft that was failing, causing the production line to shut down. Appointed to the Investigation team after only six days on the job and conducted daily briefings with several executives, including the Vice President. Secured enough parts to get the production line back to capacity, worked through the fault tree, and developed a spreadsheet to track all suspected components and their measurements, which resulted in the identification of the units and final root cause determination. Show less

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  KBR Careers - Gov Solutions

  Sept 2020 - Nov 2022

  Operations Excellence Manager

  Responsible for the administrative and operational leadership of the manufacturing product line within program guidelines established by the Program Manager, customer, or contract stipulations. Conducts current-state assessment of business processes and drive improvements through variance reduction, waste elimination, visual management, and standard work practices.Work across various functions to facilitate, develop, document and measure end to end processes utilizing process improvement methodologies, tools, and techniques (i.e., VSM, Lean, Six Sigma, DMAIC, PDCA, A3, Kaizen).Select AccomplishmentsDeveloped visual management systems for KBR Surgical Mask Facility to track trends and collect data to improve KPI’s that led to a 50% production increase over a one-month timeframe.Worked with a diverse team consisting of managers, human resource specialist, and third-party contractors to resolve a large-scale payroll issue caused during mass hiring resulting in over 100 payroll issues being resolved for employees before the holidays. Show less

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  HomeSafe Alliance

  Nov 2022 - now

  Operations Excellence Manager