MICHAEL FAVUZZI

Responsible the build and test of the pneumatic mechanisms used on Falcon 9’s 1st Stage Booster and Starlink satellite’s deployment system. After two years I transitioned to leading the build and test operations for a high-mix, medium-volume manufacturing resource producing hundreds of solenoid valve manifold subassemblies each week.

• Dispositioned over seven thousand manufacturing non-conformances in a fast-paced environment and conducted root cause analysis to implement more repeatable production processes and drive continuous improvement projects.
• Implemented automated DC torque tools which reduced torque and verification labor by 25% to facilitate 1.5-day Stage 2 rate.
• Reviewed complex test data from mechanism and pneumatic valve tray assembly tests to evaluate functional performance, resolve build anomalies, and conduct root cause investigations to inform potential mitigations to drive corrective actions.
• Analyzed historical test data to convince a cross-functional group of engineers to eliminate functional testing from the component level and rely on an analogous checkout at the final integrated level, saving 500 hrs of test labor annually.
• Leveraged historical MES data to identify an assembly with abnormally low first pass yield. Created a Standard Repair Procedure to eliminate $30,000 dollars in rework annually and eliminate 40% of the assembly’s defect landscape.
• Created work instruction template for the build & test of high mix pneumatic manifolds to align requirements & cut non-value-added processes. Eliminated 1 hr per assembly while adding contingent rework paths, eliminating deviation issues by 25%.
• Served a primary reviewer of new/updated manufacturing instructions, specification, and test procedures for safety, completeness, efficiency and conformance to product requirements.
• Used NX to completed many tooling designs of manufacturing assembly fixtures, as well as test hardware for completion of pneumatics and structural testing.

Served as a technical leader in the Fluid systems manufacturing shop focused on developing new engineers & specialists through 1-1 coaching with new members, creating documentation and guides, challenging and guiding their thought processes.

• Mentored and provided technical leadership to junior engineers and shared expertise and provided technical guidance.
• Authored a “playbook” of common defects with associated rationales, and rework procedures to improved repair instruction quality, and decrease time to address recurring issues, allowing engineering to focus on process improvements.

Fluid systems manufacturing for Falcon 9 and Dragon spacecraft in a high volume, high mix shop with broad responsibilities from forming, to tube fabrication, OTW and TIG welding per AWS D17.1, NDE inspections (VT, PT, RT) cleaning and pressure testing.

• Performed trade study to compare problematic welded casting to a new welded machined bar stock alternative. The design change reduced cost per 1st stage by $10,614 and FPY increased from 50% to 90% on par with other TIG welded assemblies.

Served as a Tactical Manufacturing Engineer for Orbital Tube Welded (OTW) Stage System Manifolds, Semi Automated TIG Welding of the Transfer Tube, and Spinforming and machining of Tank Domes. Helped drive requirements for bolted thrust structure redesign.

• Arranged tensile testing of aluminum welds with varying heat inputs, performed data review and worked with the design and weld engineers to increase the acceptable limit of repairs based on strength knock down to reduce scrap rate.