David G. Shafer, M.S. Instructional Designer
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What I have done:
American Airlines

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​Overhaul maintenance
  • Passenger seats
  • B757 when they came in for MBV's
  • Galley spars
  • Forward and aft cargo doors
  • Fuel tank plates 
  • Flight control surfaces
  • Rolls Royce RB211 fan case
Production planning 
  • Include strategic actionable front end monitoring
  • Performed analysis on lost parts or late offload parts and used the data to solve non-visual material loss
  • Created a visual rack system that reduced DIS by 25%.
  • Implemented a visual control system decreasing WIP by 10%,DIS by 20% and increasing integrity, reducing rework,
Instructional Design
  • Flight Attendant training
  • LMS changeover
Maintenance Auditor
  • Logbook cutover project
  • Overnight and base maintenance maintenance auditing

What I did in the 
United States Marine Corps
USMC – CH53 A, D and E Models 1988 - 1994

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  • noWorked off blueprints to move balance rivets as part of an Airframe Directive in the 100 hr Phase Inspection shop
  • Moved standoffs to facilitate avionics rerouting of wire bundles. Inspected, serviced and treated corroded viscous dampers on the main drive train
  • Rigged and adjusted flight controls
  • Performed main rotor head removal and replacement with 10 hour torque check and re-safety wire
  • Removed and replaced Dzus fasteners where required
  • Performed inspections on entire flight control cables looking for frays, loose toggle bolts or missing safety wire at connections
  • Used cable tensiometer to check for loose cables
  • Removed and replaced drive belts at nose gearbox
  • Inspected chip detectors at all gearboxes and sent questionable finds to calibration lab for further inspection.  
  • Made annotations on work cards specifying size and amount of metal found

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