// HIGH-CONSEQUENCE MANUFACTURING CONSULTING
Specialized engineering consultancy delivering robust design for manufacturing, high-utility tooling, and advanced process optimization for complex aerospace and mechanical assemblies.
Bridging the gap between complex engineering concepts and seamless shop-floor execution. Optimizing product geometry, tolerance stacks, and material selection to drastically lower hardware deviation rates and compress operational cycle times.
Developing high-utility, resilient mechanical equipment deployment tools. Heavy expertise in specifying and designing customized lift tools, geometric alignment fixtures, precision weld tools, and handling fixtures robust to ongoing assembly revisions.
Analyzing existing workflows to isolate vulnerabilities and scale efficiency. Engineering tailored solutions for specialized forming, modern automation, asset relocations, and structural equipment overhauls.
Process parameters, mandrels, tooling parameters, and machine selection for high-precision domes and nozzles.
Weld schedule development, qualification, and mechanical characterization across TIG, MIG, laser, EBW, and VPPAW applications.
Robotic cell implementation, layout integration, optimization workflows, and custom robotic tooling.
Subsystem overhaul, geometric calibrations, spindle reliability improvements, and localized retrofits.
Reliability updates within industrial programming environments (Siemens TIA Portal, Allen Bradley Studio 5000).
Reliability-Centered Maintenance (RCM) strategies fueled by real-time IoT condition-based monitoring dashboards.
McGee Creek Systems is directed by a former SpaceX Manufacturing Engineer with deep background managing mission-critical flight hardware sub-assemblies for the Falcon and Raptor programs.
Successfully optimized advanced vehicle sub-assembly build tempos, driving delivery targets down from a 15-day layout footprint down to a high-density 2.5-day build rate. Accomplished via systemic tooling redesigns, streamlined non-destructive inspection integration, and aggressive structural hardware deviation mitigation profiles.
Orchestrated the architectural disassembly, relocation, physical calibration, and flight-hardware validation commissioning steps for heavy capital machinery layouts—including large spinform lathes, bridge cranes, and high-precision multi-axis robotic cells.
Qualified safety-critical plasma-welded dome configurations under stringent NASA human-rated flight metrics, validating physical material limits and structural allowable metrics through granular material parameter evaluations.
Whether you need specialized tooling design, support handling complex hardware non-conformances, or structural machinery upgrades, let's get down to the data.