Mr. Zil Kamal Mokhtar, ICBB, B. Eng (Hons)

ASSOCIATE

Lean Six Sigma Black Belt Consultant

Experienced professional with a demonstrated history of working in the aerospace/aviation, manufacturing and service sectors. Skilled in Process Excellence and Business Excellence, Analytical Skills, Product Reliability Improvement, Customer Service, and Project Management. Strong engineering professional with a Bachelor of Engineering – focused in Aeronautical Engineering from Imperial College London and Diploma of Associateship of the City & Guilds of London Institute (ACGI) in Aeronautical Engineering. Certified and experienced Lean Six Sigma Black Belt, Certified ACE Associate and Process Excellence Practitioner.

  • BEng (Hons) in Aeronautical Engineering – Imperial College of London
  • Diploma of Associateship of the City & Guilds of London Institute (ACGI) in Aeronautical Engineering
  • Certified Lean Six Sigma Black Belt
  • Certified ACE Practitioner
  • EASA Post Holder – 2016
  • Design Approval Signatory – 1997 to 2012 (Malaysian Department of Civil Aviation)
  • FAA-DER Delegated Engineering Approval – 1997 (GE Aviation engines)
  • Registered Engineer (Aeronautical) – 1993 (Board of Engineer Malaysia Ref Number 22734)
  • Has expertise with the assembly and operation of modern gas turbine engines. Has worked with aircraft engines for more than 20 years dealing with engine assembly and disassembly, tooling, design, testing, and maintenance. Has expertise in the process of engine parts cleaning, inspection, and repair (including special processes such as Shot Peening, Blasting, Plasma Spray, HVOF, Laser and Arc Welding, Heat Treatment and VPA Coating in Furnace). Has experience conducting facility (engine shop) reviews. Has provided gas turbine shop representation, on-site representation, gas turbine engine document reviews for traceability and AD compliance, shop audits, and engine technical/performance assessments. Additionally, has experience in purchasing and sales of engines, modules, parts, and tooling. Has expertise on engine on-wing inspection requirements, engine removal scheduling, engine shop selection, engine workscope development and requirements, engine maintenance training, and engine testing. Has experience with analyzing the causes for engine failure including poor operation, loss of exhaust gas temperature margin, and foreign object damage.
  • Has experience in New Product Introduction meeting FAI requirement. Familiar with Pratt & Whitney, GE, CFMI and Rolls Royce engines as well their industrial and marine derivatives. Familiar with Boeing and Airbus Air Management System components repair and overhaul.
  • Experience in EASA Part 145 Maintenance Organizations/FAA Part 145 Repair Station and DCAM Part 145 Approved Organization.
  • Familiar with ISO9000, AS9100 Quality Management System and ISO14001 Environmental Management System and OHSAS 18001 Occupational Health and Safety Assessment.
  • Lean Six Sigma Project Identification, Selections & Execution.
  • Lean Six Sigma Project Consultancy and Training Material Development.
  • Problem Solving Tools Training and Facilitation.
  • Project Management activities in Process Improvement.
  • Process Certification.
  • 2016–2019: Provided leadership and technical consultation for New Product Introduction and MRO operation with turnover in excess of USD75M annually. Additional role as Process Excellence/Business Excellence lead to ensure the business meet Quality, TAT, Cost and product performance and reliability expectations. Products: Boeing 787 Dreamliner CACTCS Pack System components i.e. Quad Heat Exchangers, Air Cycle Machines, Large Galley Heat Exchangers, Nitrogen Generation System and Airflow Control Valves and Doors Actuators. Boeing 777 Air Management System components i.e. Heat Exchangers, Air Cycle Machines, Condenser Reheaters, Flow and Control Valves. Airbus A380 Heat Exchangers and Air Cycle Machines. Customers: Boeing, Airbus, major airlines – SIA, Cathay Pacific, Emirates, Qatar, KLM, American Airlines, Japan Airlines, ANA and Korean Airlines and global airlines customers.
  • 2015: Provided technical and management consulting services for Aviation AOC, MRO, ATO and Aerospace Industry. MIGHT Panel member for Malaysian 2015-2030 Parliamentary National Aerospace Blueprint.
  • 2015: Successfully introduced NPI Program and released substantiated OEM major repairs for Aircraft Engine High Pressure Compressor Blades and Low-Pressure Turbine Blades using advance proprietary technologies. Implemented Lean DFSS with Statistical Process Control, FMEA and DOE for complex repair processes producing world class yields and OTD and stable operations with lowest cost. Investing in human capital and advance technologies to deliver On-Time, On-Cost and On-Quality product for future growth and customer satisfaction. Total annual parts repaired exceeded 450,000 parts with over USD28M annual turnover. Products: GE and CFMI Engines HPC Blades and LPT Blades. V2500 Engines HPC Blades. GP7200 LPT Blades. Customers: Major Aircraft Engines Repair Shops, airlines and aircraft part suppliers
  • 2013-2015: GEESM MCRB for CSA and T&M Shop Visits. Established Cost Target Generation Tools for Engine Shop Visit Cost. Lead repair introduction projects on assigned engine hardware/module, from kick-off to introduction into-service. Define, execute and support cost avoidance (CSA) projects to reduce engine maintenance costs associated with aviation repairs. Total saving to the CSA program exceeded USD8.6M for year 2015. Major customers: Air Asia, Malaysia Airlines, Japan airlines, Asia Pacific airlines, North American airlines and Indian airlines.
  • 2011-2013: Developed new CFM56-7B Engine Overhaul Capability – IT System Readiness and Test Cell System Upgrade and Tooling/Fixtures. New Machines Investment. Developed Web based integrated SupportCentral application for paperless MRO operations. Implemented Biometric Time Attendance Integrated with Leave/Payroll System. Ensured infrastructure readiness for SAP system. Total investment over USD3.5M successfully completed.