FROM PROTOTYPE TO 15,000+
Engineering aerospace propulsion for repeatable scale.
Led aerospace propulsion NPI, manufacturing engineering, quality, and test to transition BLDC motors, ESCs, propellers, and power systems from prototype builds to 15,000+ units/month.
Client
Vector Technics
Year
2023–2024
Industry
Aerospace Manufacturing / Electric Propulsion
Turnaround time
NPI, BLDC Motors, ESC, DFM, DFA, DFMEA, PFMEA, SPC, GD&T, Root Cause Analysis, Production Readiness, High-Rate Manufacturing, ISO 9001:2015, MIL-STD-810G
The Challenge
A propulsion system that works in development is not yet a production-ready product. Scaling required controlling variation across electromechanical assemblies, tooling, processes, test methods, and operator execution while preserving performance and reliability.
My Role
I operated across engineering, manufacturing, quality, and test, serving as the cross-functional interface for NPI and production readiness.
Technical Approach
Led NPI from engineering builds through production release
Applied DFM/DFA to improve manufacturability and assembly repeatability
Used DFMEA/PFMEA, SPC, RCA, and corrective action to reduce recurring failure modes
Managed GD&T and tolerance stack-ups affecting concentricity, rotor-stator air gap, and dynamic balance
Standardized work instructions, build sequencing, tooling readiness, and production documentation
Supported ISO 9001:2015 quality processes and MIL-STD-810G-related qualification activity
Impact
Production scaled from 300 to 15,000+ units/month while propulsion reliability and operational uptime improved by approximately 40%.
Product iteration cycles were reduced by 35%, and the product catalog expanded to 94 aerospace-grade components.
Highlights
300 → 15,000+ units/month
~40% reliability improvement
35% shorter iteration cycles
94 aerospace-grade SKUs
