Vasudev Bhise

Project Description

Global Management of Tactical Technical Support of Rolls‑Royce large civil engines providing Engine, Module and Component Serviceability Assessments and Repair Solutions to support immediate Engine Overhaul Operations.

Responsibilities

• To develop repair definition and repair sources by optimizing concepts and solution within agreed engineering and business constraints.
• Return service run components back to serviceable condition utilizing various manufacturing/lab processes.
• Define and maintain technical requirements for component repair processes and ensure compliance with them.
• Identify opportunities for new repairs based on condition of service run components and define limits within repair is technically feasible. This can include definition of dressing geometry or definition of maximum allowable material removal.
• Establish that the technical data requirements are compliant to airworthiness standards and ensure repairs and limits are safe, durable, properly substantiated meeting the quality requirements of component.

Key Skills Acquired

• Good Knowledge of functionality of relevant components and systems with full consideration of the intended form, fit and functions of the product.
• Knowledge of systems, sub-systems and component design and the effect of repair of components on the greater systems, specifying and managing the evolving trade-offs so that the result satisfies the captured requirements.
• Knowledge of material properties for the selection of material or execution of process. Includes chemistry, structure, mechanical and chemical performance.
• Familiarity with gas turbine materials, part design, manufacturing process, heat treatment, special process likes coating, joining, Cleaning, Plating and NDT.
• Technical understanding of maintenance, repair, overhaul, and regulatory requirements in the commercial aircraft industry relevant to Repair Engineering.
• Sound knowledge of developing repairs for metallic and/or composite structures and various inspection methods and common defects. Includes Core Engine Components and Non-Modular Components including Nacelle.
  Sound knowledge about General Arrangements of Aero‑Engines.

Key Characteristics

• Review the technical variances raised by overhaul shop and provide viable disposition to the variance raised to enable dispatch of the engine. The repair solutions involve salvage of components by welding, machining, fabrications, metal spray and various other mechanical processes.
• Perform the detailed investigation of technical variance requests raised from overhaul shops, understand the variance reported, assess the parameters of the raised variance and its impact on the component, mating component and engine's performance.
• Create engineering documentation after discussing with various engineering stakeholders for their concurrence on the acceptance of the provided solution and ensuring that all the manufacturing, quality and safely requirements needed for the component / module is taken care in the solution document.
• Develop technical documentation to support the engine programs and meet the design, regulatory and urgent operational requirements.
• Work with production engineering to understand design changes and evaluate impact to structure maintainability, reparability, and maintenance manuals (CMM, SRM, AMM).
• Improvement activities with close involvement with overhaul facilities and component repair vendors worldwide.
• Prioritize and deliver the solution documents to meet the various gates of Engine services process.
• Providing technical and procedural direction and support for internal and external team members whilst ensuring compliance to processes.
• Co-ordinate with Overhaul Shop Business Unit and Shop representatives on Operational support activities.

Achievements

• Reduced scrap rate of critical engine components by 50% by delivering technical solutions.
• Repair Engineer – Design, first-level Rolls-Royce signatory authority to author and approve repair instructions for Rolls-Royce Civil Large Engines.
• Received an award in QuEST Global for providing on‑time repair solution for various overhaul shops.
• Received an award in QuEST Global for maintaining the best quality in delivery.

Project Description

Concessions and DARs are the complete solution to ensure speedy disposition & reduction of manufacturing non‑conformances.

Responsibilities

• Analyses, conducts root cause analysis and develops dispositions for design non-conformances.
• Integrates producibility & manufacturability knowledge, information, and requirements into the acquire and define program phases as the designated Integrated Product Team (IPT) interface.
• Integrate between Design, Stress and CDG (Component Definition Group) functions to achieve the overall best and most cost/time efficient technical solutions.
• Participates in the implementation of manufacturing plans. Investigates technical problems.

Key Skills Acquired

• Knowledge of GD&T and tolerance stack up is utilized to optimize the design to reduce re‑work for the components to be manufactured.
• Experience with Aerospace Manufacturing, Fabrication, Assembly Processes and Technologies.
• Good background of Engineering Design concepts along with Manufacturing processes and quality system.
• Working knowledge with CATIA/NX Modelling software's.
• Technical writing on the functionality of part and Design intent of features to analyze the fit form and function of Non-conformed for Gas turbine part in Installation/Compressor/Turbine/ Combustion & Casing.

Key Characteristics

• Liaising with Rolls‑Royce engineering specialists and Design engineer to understand the design requirement to aid manufacturing process. Ensure all interfaces between components are established and agreed upon by Engineering design teams of interface parts and engine systems.
• To review the design requirement and to assist in the creation of optimum design solutions that will satisfy all manufacturing requirements.
• To evaluate the definition change requested by the Rolls‑Royce design engineer and the supplier and co‑ordinate with Chief Design Engineer to authorize the definition change.
• Conducts Producibility to ensure that manufacturing process capability matches requirements.
• Reviewing concessions and recommending for drawing change through Definition Alteration Request (DAR) process. Fit, Form and Functionality analysis of various components with defects through concession, DAR TAD's.
• Carrying out tolerance stack analysis, layout in UG, interaction with various specialists like Stress engineer, Air system, Materials engineer.

Achievements

• The delegation was provided by the Chief of Configuration and Chief Design Engineer to release an authorized definition change made on the drawing and engineering models to the supplier for manufacturing process.
• Awarded for approving highest number of design definition for a particular month by Chief Design Engineer, Rolls-Royce.

Project Description

Responsible for Civil Large Engine Technical Publication and Overhaul Method included Service Bulletins.

Responsibilities

• Method development and support, novel and new methods and existing method support across both new products and fleet.
• Collaborate between Original Manufacturer, Overhaul Shop, Tooling Team and Repair team to analyze gaps and propose optimized methods.
• Analyze fleet data to substantiate manual revisions and provide design-based recommendations.
• Review a diverse array of damage profiles inherent of gas turbine engines to assess serviceability and reparability with compliance to manual publications.
• Create engineering documentations and necessary revisions in Technical Publications to address maintenance issues and improve manual maturity.

Key Skills Acquired

• Overhaul engine Methods and Tooling Engineer responsible for the creation, compilation, approval, and delivery of new and innovative engine strip and build methodology for the Rolls-Royce Trent 900, Trent 1000 Pack C, Trent1000-TEN, Trent XWB-97 and XWB-84 engine fleets, both within Rolls-Royce organization.
• Process Failure Mode Effects Analysis (PFMEA), Design Failure Mode Effect Analysis (DFMEA) and Risk management. Hands on experience on adopting Industry standards like ASD S1000D, ATA ISpec 2200.
• High level of systems thinking, leadership and integration skills.
• Proactive identification of anomalies in current manuals, propose optimization and improvisation of current process, tools and methods by thorough verification.

Key Characteristics

• Author and Approve Technical Variances to clearly communicate and justify repair instructions to various international maintenance facilities as well as in-field customers.
• Worked on measurement capabilities, PFMEA and DFMEA for continuous improvement.
• Provide solution to in-service issues by conducting Event Investigation.
• Manage creation of Cleaning & Inspection manuals.
• Creating of Service Bulletins for ‘In-Shop' and ‘On‑Wing' components.
• Collaborate between Original Manufacturer, Overhaul Shop, Tooling Team, and Repair team to analyze gaps and propose optimized methods.
• Experience in resolving customer queries / issues in service bulletins, modification bulletins etc
• As the Service Bulletins Team lead, I adopt coach style leadership techniques to ensure as a team we set the standards of managing workload, responsiveness to technical queries and control of quality and cost.
• Current role as the Methods Engineering Technical Champion leading the deployment of APQP, Manufacturing engineering process and capability to the development of Methods, Manuals and ICA for the Aftermarket and MRO.

Achievements:

• Received the Technical Signatory to approve all ICA as a first level of approver for Rolls‑Royce CLE Engines. Includes Repair and Methods ICAs.
• Technical Champion for AS91465 (Aerospace Standard) for Overhaul Methods Engineering.
• Process owner and lead for Technical Publications driving transformation to bring RR Technical Publications to the forefront and ensure they reach their full potential.
• Awarded for managing and leading the Service Bulletin Team. Excellent support in executing the L2VRs. Being champion and trainer for C3 process, developing the team member, helping customer and various stake holders to adhere to APQP process. Building customer trust and expectation to a highest level.