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Relentlessly rethinking rotorcraft

Having entered the industry with Bell Helicopter almost 12 years ago in a structural research role, engineer Dave Dennison has advanced to become assembly line manager for its 525 programme, in Amarillo, Texas.

6 January 2015 5 min read
<p>Having entered the industry with Bell Helicopter almost 12 years ago in a structural research role, engineer&nbsp;Dave Dennison has advanced to become assembly line manager for its 525 programme, in Amarillo, Texas.</p>

<p><strong>Where did you start out?</strong></p>

<p><em>My first job was at a private golf&nbsp;course in high school, working as&nbsp;a cart boy, caddie and golf shop&nbsp;attendant. I worked for seven&nbsp;years at that job all&nbsp;the way&nbsp;through college, and learned a lot&nbsp;about how to deal with&nbsp;customers&nbsp;with high expectations.</em></p>

<p><em>My&nbsp;first aviation job was working for&nbsp;Bell Helicopter right after I graduated&nbsp;from Georgia Tech. I was hired on to the research structures&nbsp;organisation as an airframe&nbsp;designer. Some of the early projects&nbsp;I worked on involved advanced&nbsp;composites design, design&nbsp;for survivability and&nbsp;advanced tiltrotor concepts.</em></p>

<p><strong>What came next?</strong></p>

<p><em>I have worked in a number of&nbsp;roles and programmes primarily&nbsp;in airframe design. I was a designer&nbsp;and technical lead on the&nbsp;Armed Reconnaissance Helicopter&nbsp;(ARH) programme helping&nbsp;build four prototype aircraft, and&nbsp;helped start a production line for&nbsp;a US Army programme.</em></p>

<p><em>After&nbsp;that, I was the&nbsp;airframe technical&nbsp;lead for a single-engined light&nbsp;helicopter development programme,&nbsp;transitioned into the&nbsp;technical lead for the Bell 429&nbsp;wheeled landing gear variant,&nbsp;and the technical lead for a cost&nbsp;and weight reduction programme for the Bell 429.</em></p>

<p><em>This all&nbsp;led to being named the airframe&nbsp;supervisor for the brand new Bell&nbsp;525 Relentless. I helped lead that&nbsp;team through the conceptual,&nbsp;preliminary and detail design of&nbsp;the airframe structure, which has&nbsp;personally been the most rewarding&nbsp;role in my career. Building on&nbsp;that experience, I transitioned to&nbsp;a manager role, leading the systems&nbsp;integration design team on&nbsp;the 525.</em></p>

<p><em>Finally, I transitioned&nbsp;out of engineering for the first&nbsp;time, as the assembly manager&nbsp;for the 525. I started at Bell Helicopter&nbsp;in July of 2003, so I am&nbsp;quickly approaching 12 years&nbsp;now. I have been in my most recent&nbsp;role for six months.&nbsp;</em></p>

<p><strong>How large is your team?</strong></p>

<p><em>My team is currently approaching&nbsp;60 highly motivated individuals.&nbsp;These include mechanics,&nbsp;electricians, supervisors and&nbsp;managers. This is my first venture&nbsp;outside of engineering, and&nbsp;has been a terrific experience.</em></p>

<p><em>Few people get the opportunity&nbsp;to heavily influence the design&nbsp;of a cutting-edge rotorcraft, and then get to build it after the design&nbsp;is complete. The&nbsp;learning&nbsp;opportunity is immense. We are&nbsp;currently building flight-test vehicles&nbsp;to support our certification&nbsp;programme, but later this&nbsp;year will start building production&nbsp;aircraft.</em></p>

<p><em>We will be accelerating&nbsp;our line quickly to meet&nbsp;the huge market demand for this&nbsp;product. My primary objectives&nbsp;are to make sure the build of the&nbsp;aircraft is on schedule, on budget,&nbsp;safe, and of high quality.&nbsp;Additionally,&nbsp;I am responsible for&nbsp;ensuring the long-term strategy&nbsp;of the Bell 525 production and&nbsp;make sure it meets our programme&nbsp;objectives. &nbsp;This allows&nbsp;me to be fairly strategic in my&nbsp;role, which is always fun and&nbsp;exciting.&nbsp;</em></p>

<p><strong>What’s the most difficult part of&nbsp;your job?</strong></p>

<p><em>The most difficult part of my job&nbsp;is keeping focused on the long term&nbsp;goals. The key to success is being able to filter out the day-today&nbsp;noise, and ensure you are&nbsp;making progress towards your&nbsp;overall big picture objectives&nbsp;every day.</em></p>

<p><strong>What’s most enjoyable?</strong></p>

<p><em>Being around aircraft is always&nbsp;exciting. The complexity of these&nbsp;machines and seeing how all the&nbsp;systems work together is fantastic.&nbsp;However, seeing the passion&nbsp;in our customers, and how they&nbsp;use these products every day to&nbsp;save lives, is really at the core of&nbsp;why we do what we do. That is&nbsp;by far the most enjoyable and rewarding&nbsp;aspect of my job.</em></p>

<p><strong>What position do you hope for?</strong></p>

<p><em>Personally, I would love to have&nbsp;the opportunity to lead a new development&nbsp;programme some&nbsp;day. I, like so many others, got&nbsp;into this business to invent new&nbsp;products and technologies. Innovation&nbsp;is incredibly exciting.</em></p>

<p style="box-sizing: border-box; position: relative; word-wrap: break-word; margin: 0px 0px 0.8em; padding: 0px; border: 0px; font-family: Arial, Helvetica, sans-serif; font-size: 15.1999998092651px; font-stretch: inherit; line-height: 21.2799987792969px; color: rgb(77, 77, 77);"><em style="box-sizing: border-box; position: relative; word-wrap: break-word; margin: 0px; padding: 0px; border: 0px; font-family: inherit; font-size: inherit; font-variant: inherit; font-weight: inherit; font-stretch: inherit; line-height: inherit;"><strong style="box-sizing: border-box; position: relative; word-wrap: break-word; margin: 0px; padding: 0px; border: 0px; font-family: inherit; font-size: inherit; font-style: inherit; font-variant: inherit; font-stretch: inherit; line-height: inherit;">Looking for Engineering&nbsp;vacancies? Check out our listings online by&nbsp;<a href="http://jobs.flightglobal.com/jobs/aerospace-engineering/?intcmp=FGJOB-careers_hub_ww-dave_dennison">CLICKING HERE</a>.</strong></em></p>

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