Our Work

Led “on time, on budget” certification of Trent 800 engine (for Boeing 777) as Chief Development Engineer. Included some novel approaches to certification including first RR use of the USAF “AEDC” altitude test facility in Tennessee and the first concurrent European and US engine certification (JAA and FAA).

Sole Engineering representative on BMW RR JV task-force to make the smooth transition from Product Development into aircraft certification/ entry into service, series production and in‐service support for business jets. Reported to Rolls-Royce/ BMW Joint Venture executive board. The prime objective of the Task Force was achieved; I presented all findings and recommendations (which were implemented) to the shareholder committee.

Accountability for all aspects of Transmissions and Structures Engineering activity on Rolls–Royce gas turbine engines as Engineering and Technology Director. Although not a subject matter expert, I had direct and/or professional Leadership of over 300 Engineers from all disciplines across 6 globally distributed sites. Technical highlights included design of the world’s highest power to weight gearbox on the JSF Liftfan™ with use of “follow the sun” working. I chaired the National Advisory Committee (NAC) on transmissions and had accountability for the transmissions Nottingham University Technology Centre (UTC).

Led all experimental activity for Civil Aerospace as General manager accountable for a team of 850 people with a c.£160M annual budget in today’s money including capital investment. Key deliverables during this time included establishing capability for the Trent 900 development programme and resolving Industrial Trent combustion and aero-acoustic problems. I also led the downsizing of this part of the business post 9/11 and in the process Integrated experimental assembly and test into one team along value chain principals and introduced a new team based working job structure with new terms and conditions.

Defined, made business cases for and delivered test capability strategy for RR gas turbine portfolio (Civil, Defence and Industrial). Rationalised current capability, halving the number of existing facilities, and defined strategic needs for all new facilities required. Played strategic executive role in their delivery. Total of c.£400M of projects over 15yrs. This included rationalising the existing capability buy closing obsolete or duplicate facilities and delivering the following key capabilities:

• ANECOM compressor aerodynamic and fan noise rig test facility in Wildau, Germany rationalising and updating 3 facilities from different locations. This was a joint venture business at the time in which RR was a minority shareholder.
• Consolidation of combustion test capability from defence and civil aerospace businesses into one location and capability enhanced to support industrial Trent. Subsequently this was all relocated with DLR in Cologne to allow shared use and cost of air raising plant with other users.
• Closure of the historic outdoor experimental test site at Hucknall for environmental noise reasons and re-distribution of the capability without disruption to the business
• 58 bed in Derby to absorb the certification “share price sensitive” critical tests from Hucknall and provide essential test capacity at improved effectiveness to support the entire Trent engine portfolio
• The establishment of new outdoor test capability for noise, cross wind and cyclic endurance at NASA John C Stennis in Mississippi USA. 2 new outdoor test stands with associated equipment.
• Production engine build and test capability at Seletar in Singapore and an MRO test facilities in Singapore (SAESL) and Germany (N3)
• Mechanical Test Operations Centre in Germany including the ability to conduct fan Blade Off and bird shot testing in a vacuum chamber. This project rationalised a large number of facilities scattered across multiple sites into one purpose built centre reducing costs, increasing efficiency and reducing lead-times to deliver critical test data.
• Strategy to replace use of AEC ground based altitude test. This included delivery of a joint venture test capability “GLACIER” with our competitors Pratt and Whitney. This is a ground based icing facility in the Canadian Tundra at Thompson Manitoba. The winter day temperatures here allows the natural ability to generate ice particles. The icing facility will be complimented by a universal Boeing 747-400 flying test bed which is currently undergoing modification.
• Conceived and launched “Test Execution and Data System”(TEDS) project as a new flexible standard for instructing, capturing and managing critical test data. This includes transactional IT, real time safety critical data acquisition system and back end data management and distribution. The system is based on a DDS backbone, is flexible, scalable, industry standard and supplier and data format agnostic.

Envisioned and conceived the power gearbox rigs for Ultrafan™ testing in Germany and led technical governance during architectural approach, design, construction and commissioning. Convinced Main Board Engineering Director of the need for the facility and obtained capital funding including German government contribution. Forged relationship with RENK Gmbh as main contractor for what is the highest speed/ power combination gearbox test facility ever built. This was the 1st application of the TEDS data system.

Led the architectural aero-acoustic and physical sizing of the new 80 test bed in Derby for Ultrafan. The bed is currently in construction and is due to be operational in 2021

Co-chaired ARAC industry working group on alternate 150hr endurance type-test airworthiness regulation (aero gas turbine OEMs, Airbus, Boeing and major airworthiness authorities - FAA, EASA and TCC).

Led measurement and test strategy to identify and resolve major Trent 1000 service problem. This was a more than $1.5Bn problem threatening company survival.

Led, programme managed and moderated a business critical independent maturity review on Trent engines for RR Group Executive Leadership Team. Prior to leaving I played key role in subsequent follow-up with substantial process, governance and product changes being implemented as a result. The value of this could be up to c.20% of civil aerospace total care revenues of $5Bn pa. I Co-authored and presented the report to the RR CEO (Warren East).

Co-authored "Gas Turbine Aero Ground Testing" section of Wiley's "Encyclopaedia of Aerospace Engineering".

Mentor and coach engineers and project technical leaders to achieve their career goals. Sit on promotion boards up to and including “Fellow” level. Introduce and close out RR “Specialist Academy”.

Defined optimum organisation of the development and experimental value chain in Civil Aerospace which was implemented by the engineering VP as “Development and Experimental Engineering”.

Participation as an audit team member on business and technical risk governance gates for all manner of new projects at various stages of their lifecycle.