D. Thomas McAvoy
Warrenton
Summary
Highly motivated leader with a proven track record of taking objectives, even loosely defined ones, and creating detailed action plans for a team to effectively execute. Good communication and critical thinking skills support ability to quickly resolve issues and make progress. My focus on the development of individuals and area leaders has resulted in successful teams achieving our objectives.
Overview
35
35
years of professional experience
Work History
Director of Operations
BAE Systems
07.2022 - Current
- Responsible for 6 direct reports and 100 Production and Support Teams for three electronics Manufacturing Factories, reporting on Quality, Cost and Schedule performance and action plans
- Championed team to develop technical/product roadmaps and CapEx plan to deliver on 5-10 year integrated business plan
Technical Operations Manager
BAE Systems
10.2019 - 07.2022
- Leading engineering team and support personnel of three Manassas Production Factories (Component Assembly, Circuit Card and Microwave), including solutions for 45nm packaging and circuit card integration
- Instituted cross-functional team to develop packaging tech roadmap
- Developed strategy across the factories to perform product Risk Assessments and PFMEA’s, and create control plans
- Created Root Cause/Corrective Action Training and development discussions for cross functional team members to improve overall team performance
- Responsibilities include Equipment Maintenance and Process Documentation
Factory Manager
BAE Systems
08.2016 - 10.2019
- Led the Technical Transfer of Microwave Product Assembly from a New Hampshire factory to Manassas
- Coordinated transition activities among three sites, including engineering, production, program management, supply chain and quality
- Ultimately we received a One Team Award for this effort
- Created Core Values and Personnel Development expectations for Team
- Managed a team of 35 including 2 Shift Supervisors, support engineers and production staff
- Defined a metrics driven approach so that factory continues to achieve monthly delivery targets
- These programs were months behind schedule prior to the transition
Technical Lead, Operations
BAE Systems
03.2013 - 08.2016
- Site Lead for division wide Quality Improvement initiative
- Certified as AS9100C / AS9145 Auditor
- Champion of effort to increase effectiveness of manufacturing and quality processes in alignment with standards
- Coordinated the Process Development effort to upgrade quality and reliability of radiation hardened components via process, tooling and material improvements
- This includes new product development utilizing 45nm silicon process technology
- Lead troubleshooter for Space Products and Systems business area utilizing Kepner Tregoe (KT) Methodology
- I actively facilitated at least 10 issues across the business per year
Manager, Module Design and Assembly Operations
BAE Systems
12.2009 - 03.2013
- Managed Team of 14 Engineers and Technicians supporting Module Assembly Factory
- Trained on KT Problem Solving and Decision Making (PSDM) methodology, and PSDM Facilitator
- Utilized PSDM methodology as a development objective for the engineering team
- Championed cross-functional effort to integrate packaging design in with wafer and board/system level design activities, to implement 'Design for Success' methodology
Senior Engineer
BAE Systems
07.2007 - 12.2009
- Lead Process Engineer for advanced semiconductor packaging area
- Developed enabling packaging process technology roadmap to support radiation hardened semiconductor line
- Directed the technical transfer of thermal imager product line from BAE Lexington to Manassas
- Coordinated engineer and technician training, new equipment procurement and qualification, process documentation, materials planning and product qualification per schedule and cost targets
- Managed activities to improve yield, reduce defects, reduce cost and improve manufacturability of assembly area
Section Manager, PVD/Ion Implant Section
Micron Technologies
07.2002 - 07.2007
- Managed PVD-Implant section for initial 300mm facility for Micron from initial pilot DRAM line to full capacity, highly automated production line for both DRAM and NAND Flash Devices
- Managed career growth plans for employees, numbering up to 64 leads, engineers and technicians
- This included interview/hiring, reviews, promotions, etc
- Reported Equipment and Production metrics to upper management on a weekly basis
- Participated on worldwide (colleagues from Japan, Singapore, Italy and US) equipment and technology team for PVD and Implant areas
- Developed technical roadmap with team, and strategies for technology transfer
- Initiated benchmark studies to improve process and equipment performance on DRAM and NAND Flash products for technology nodes 0.11um down to 0.07um features
Engineer/Team Leader for PVD/CVD Department
Dominion Semiconductor
06.1997 - 07.2002
- Created process qualification strategies for 18 new PVD and CVD deposition tools to support Memory Manufacturing (DRAM and Flash Memory)
- Championed new hardware qualification of advanced aluminum metallization process from vendor demo, unit qualification, marathon test verification and reliability hardware testing
- Developed strategy to review in line defect data and reaction plan, including automated qualifications to eliminate data integrity issues
- Trained in 6-Sigma Quality Initiative (Green Belt), using statistical approach to project management and execution
- Project improved equipment uptime by 5.2% by reduction of key component failures
Engineer
Jet Process Corporation
09.1990 - 06.1997
- Executed research plans for development of an electronics grade thin film deposition process called Jet Vapor Deposition
- Supported writing proposals for research grants from various government agencies
Education
MS - Electrical Engineering
Yale University
New Haven, CTBS - Electrical Engineering
University of Vermont
Burlington, VTSkills
- Critical Thinking
- Root Cause Analysis
- Kepner Tregoe
- PFMEA/Control Plans
- Project Management
- Employee and Leadership Development
Community Service
- Volunteer Quality of Life+ mentor, George Mason University, Mentored a team of engineering students designing innovations to support wounded warriors., 2020-2021
- Advisory Board Member, George Mason University Nanotechnology; Northern Virginia Community College Technology Advisors
- Volunteer, Assistant Scout Master, Cub Scouts and Boy Scouts of America, 2003-2018
- Baseball and Basketball Coach, Fauquier County Youth Sports, 2003-2012
- Volunteer, Pat’s Q Memorial Golf Tournament, 2008-Present, Annual net proceeds typically >$30k to support a scholarship for a deserving high school senior accepted to James Madison University.
- Mentor, Trained and certified by the State of Virginia to mentor at risk youth., 2014-2016
Hobbies and Interests
- Avid Runner
- Hiker
- Backpacker
- Reader of Economics, History, Psychology, Finance, Leadership
Timeline
Director of Operations
BAE Systems
07.2022 - Current
Technical Operations Manager
BAE Systems
10.2019 - 07.2022
Factory Manager
BAE Systems
08.2016 - 10.2019
Technical Lead, Operations
BAE Systems
03.2013 - 08.2016
Manager, Module Design and Assembly Operations
BAE Systems
12.2009 - 03.2013
Senior Engineer
BAE Systems
07.2007 - 12.2009
Section Manager, PVD/Ion Implant Section
Micron Technologies
07.2002 - 07.2007
Engineer/Team Leader for PVD/CVD Department
Dominion Semiconductor
06.1997 - 07.2002
Engineer
Jet Process Corporation
09.1990 - 06.1997
BS - Electrical Engineering
University of Vermont
MS - Electrical Engineering
Yale University
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