This is the resource-loaded view of the CWP-700 Work Breakdown Structure. Every work package carries its named effort and cost, every hour traces to a named person on the Resource Plan, and effort is split by program phase — because Phase 1 and Phase 2 are not merely earlier and later, they are staffed by different people doing different work.
79
WBS line items
68
Loaded work packages
50
Named resources
312
Assignments
100,568
Total effort (h)
01 How this WBS is loaded
Each work package names one accountable owner plus the named contributors who perform the work. On a production program that distinction is unusually literal: the engineer who owns a work package is rarely the person whose hands are on the part. A layup work package is owned by a manufacturing engineer and performed by composite layup technicians across shifts, and a resource-loaded WBS that recorded only the owner would account for a fraction of the labour actually consumed.
The loading is allocation-aware: each person's hours come from their Resource Plan line, which carries their FTE percentage — and these vary (100%, 80%, 60%, 50%, 40%). Hours are then distributed across the packages they work on in proportion to package duration.
Cost is distributed, not recomputed. Blended rates are rounded for
presentation, so rate × hours drifts from the stated cost by a few dollars per person. Each person's
stated cost is allocated instead, so the roll-up ties to the Program Budget exactly rather than approximately.
02 Effort & cost by phase
| Phase | Scope | Resources | Packages | Effort (h) | Labor cost |
|---|---|---|---|---|---|
| Phase 1 | Qualification & First Article (6 months) | 9 | 31 | 8,216 | $755,000 |
| Phase 2 | Production Ramp & Steady-State (12 months) | 49 | 37 | 92,352 | $7,216,000 |
| Total | 18 months | 50 | 68 | 100,568 | $7,971,000 |
Phase 2 is not simply "more of Phase 1". Phase 1 runs with 9 people
proving the process can make a conforming part; Phase 2 runs with 49 proving it can make them
repeatedly and at rate. That is a 9.6× cost step and an almost entirely different team —
which is exactly why the original 14-person estimate was wrong in kind rather than merely low, and why
decision D-06 corrected NDT capacity that had been sized against the wrong phase.
A. Whitfield (Tooling Engineer) appears in Phase 1 only, and any reading of the roster that takes the
Phase 2 table alone silently loses them — the merge of both phase tables is what gives the true
50-person program team.
03 Reconciliation
| Check | Value | Result |
|---|---|---|
| Phase 1 distributed effort / cost | 8,216 h / $755,000 | = Resource Plan Phase 1 total ✓ |
| Phase 2 distributed effort / cost | 92,352 h / $7,216,000 | = Resource Plan Phase 2 total ✓ |
| Combined | 100,568 h / $7,971,000 | = Program Budget labor, $0 variance ✓ |
| Per-resource, per-phase | 50 of 50 | each equals that person's roster line exactly ✓ |
These are assertions the generator evaluates, not totals typed into a table — it refuses to emit this page if any fails. The $7,971,000 reconciled here is the same labor line that appears in the Program Charter's authorized budget.
04 Effort & cost by work stream
| WBS | Work stream | Packages | Effort (h) | Labor cost |
|---|---|---|---|---|
| 1.1 | Tooling design & fabrication | 8 | 1,484 | $132,617 |
| 1.2 | Material qualification (PPAP) | 6 | 923 | $82,859 |
| 1.3 | Initial production run & inspection | 11 | 3,311 | $290,000 |
| 1.4 | MRB-001 disposition & re-inspection | 5 | 1,434 | $127,620 |
| 1.5 | Milestone Gate: FAI Accepted | 1 | 1,064 | $121,904 |
| 2.1 | Production release authorization | 1 | 8 | $1,002 |
| 2.2 | Composite layup production | 9 | 39,134 | $2,853,263 |
| 2.3 | In-process inspection & NDT | 6 | 15,528 | $1,351,672 |
| 2.4 | MRB case management | 8 | 1,658 | $179,502 |
| 2.5 | Supplier quality & procurement | 9 | 16,141 | $1,131,787 |
| 2.6 | Preventive maintenance program (layup fixture, post MRB-004) | 1 | 2,802 | $271,349 |
| 2.7 | Program status reporting | 2 | 17,019 | $1,420,400 |
| 2.8 | Milestone: Program Closeout | 1 | 62 | $7,025 |
05 Resource loading by person
| Resource | Role | FTE % | Phases | Hours | Cost | Pkgs |
|---|---|---|---|---|---|---|
| C. Tyrrell | Program Manager | 100% / 100% | Both phases | 3,120 | $360,000 | 4 |
| R. Kessler | Quality Engineering Lead (AS9100 QMS Owner) | 100% / 100% | Both phases | 3,120 | $330,000 | 24 |
| M. Osei | Manufacturing Engineer | 100% / 100% | Both phases | 3,120 | $300,000 | 4 |
| B. Solis | Quality Inspector | 100% / 100% | Both phases | 3,120 | $235,000 | 4 |
| D. Marchetti | Deputy Program Manager | 100% | Phase 2 only | 2,080 | $220,000 | 4 |
| K. Rutherford | Manufacturing Technician (Composite Layup) | 100% / 100% | Both phases | 3,120 | $220,000 | 7 |
| L. Vance | Materials / NDT Engineer | 80% / 50% | Both phases | 1,872 | $210,000 | 5 |
| S. Pham | Supplier Quality Engineer (PPAP) | 60% / 100% | Both phases | 2,704 | $210,000 | 8 |
| T. Winslow | Manufacturing Engineer | 100% | Phase 2 only | 2,080 | $200,000 | 15 |
| B. Winfield | NDT Technician, Level II, Shift 3 | 100% | Phase 2 only | 2,080 | $180,000 | 1 |
| K. Sorensen | NDT Technician, Level II, Shift 2 | 100% | Phase 2 only | 2,080 | $180,000 | 1 |
| R. Achebe | NDT Technician, Level II, Shift 1 | 100% | Phase 2 only | 2,080 | $180,000 | 1 |
| G. Ochoa | Maintenance Technician | 100% | Phase 2 only | 2,080 | $164,000 | 6 |
| H. Winthrop | Maintenance Technician | 100% | Phase 2 only | 2,080 | $164,000 | 6 |
| E. Solberg | Autoclave / Cure Technician, Shift 3 | 100% | Phase 2 only | 2,080 | $160,000 | 9 |
| L. Sheffield | Production Scheduler / Planner | 100% | Phase 2 only | 2,080 | $160,000 | 10 |
| M. Vartan | Autoclave / Cure Technician, Shift 1 | 100% | Phase 2 only | 2,080 | $160,000 | 9 |
| N. Vasquez | Quality Inspector | 100% | Phase 2 only | 2,080 | $160,000 | 1 |
| P. Larsen | Quality Inspector, Shift 3 | 100% | Phase 2 only | 2,080 | $160,000 | 1 |
| S. Okoro | Autoclave / Cure Technician, Shift 2 | 100% | Phase 2 only | 2,080 | $160,000 | 9 |
| A. Delacroix | Manufacturing Technician (Composite Layup), Shift 2 | 100% | Phase 2 only | 2,080 | $150,000 | 9 |
| A. Restrepo | Supplier Quality Engineer (PPAP) | 100% | Phase 2 only | 2,080 | $150,000 | 2 |
| C. Nakashima | Trim & Drill Technician, Shift 3 | 100% | Phase 2 only | 2,080 | $150,000 | 9 |
| C. Okwuosa | Manufacturing Technician (Composite Layup) | 100% | Phase 2 only | 2,080 | $150,000 | 2 |
| D. Halvorsen | Trim & Drill Technician, Shift 1 | 100% | Phase 2 only | 2,080 | $150,000 | 9 |
| J. Beaumont | Manufacturing Technician (Layup), Shift 3 Lead | 100% | Phase 2 only | 2,080 | $150,000 | 1 |
| J. Whitby | Manufacturing Technician (Composite Layup), Shift 2 | 100% | Phase 2 only | 2,080 | $150,000 | 9 |
| K. Delvecchio | Manufacturing Technician (Layup), Shift 3 | 100% | Phase 2 only | 2,080 | $150,000 | 1 |
| L. Fontaine | Trim & Drill Technician, Shift 2 | 100% | Phase 2 only | 2,080 | $150,000 | 9 |
| P. Mensah | Manufacturing Technician (Composite Layup), Shift 2 | 100% | Phase 2 only | 2,080 | $150,000 | 9 |
| R. Kowalczyk | Manufacturing Technician (Layup), Shift 3 | 100% | Phase 2 only | 2,080 | $150,000 | 1 |
| T. Alvarado | Manufacturing Technician (Composite Layup) | 100% | Phase 2 only | 2,080 | $150,000 | 2 |
| I. Sondheim | Incoming Material Inspector | 100% | Phase 2 only | 2,080 | $146,000 | 1 |
| W. Fairweather | Incoming Material Inspector | 100% | Phase 2 only | 2,080 | $146,000 | 1 |
| H. Lindgren | Document Control / Configuration Management Specialist | 100% | Phase 2 only | 2,080 | $140,000 | 3 |
| Q. Whitcomb | Document Control / Configuration Mgmt Specialist | 100% | Phase 2 only | 2,080 | $140,000 | 3 |
| J. Packard | Packaging / Shipping Technician | 100% | Phase 2 only | 2,080 | $136,000 | 9 |
| K. Merchant | Packaging / Shipping Technician | 100% | Phase 2 only | 2,080 | $136,000 | 9 |
| M. Talbot | Materials Handling / Logistics Coordinator | 100% | Phase 2 only | 2,080 | $136,000 | 1 |
| S. Kandel | Materials Handling / Logistics Coordinator | 100% | Phase 2 only | 2,080 | $136,000 | 14 |
| N. Redmond | MRB Quality Engineer | 60% | Phase 2 only | 1,248 | $135,000 | 9 |
| N. Castillo | IT / Systems Support Technician | 80% | Phase 2 only | 1,664 | $125,000 | 2 |
| D. Okafor | Program Coordinator | 50% / 50% | Both phases | 1,560 | $120,000 | 7 |
| A. Whitfield | Tooling Engineer | 100% | Phase 1 only | 1,040 | $90,000 | 6 |
| J. Ferraro | MRB Chair / Sr. Quality Engineer | 40% | Phase 2 only | 832 | $90,000 | 8 |
| L. Prescott | Buyer / Procurement Specialist | 60% | Phase 2 only | 1,248 | $85,000 | 1 |
| R. Bianchi | Buyer / Procurement Specialist | 60% | Phase 2 only | 1,248 | $85,000 | 1 |
| M. Ainsley | Training Coordinator | 60% | Phase 2 only | 1,248 | $84,000 | 15 |
| V. Castellanos | EHS & Facilities Coordinator | 40% | Phase 2 only | 832 | $64,000 | 15 |
| V. Halstead | EHS & Facilities Coordinator | 40% | Phase 2 only | 832 | $64,000 | 15 |
| Total — 50 resources | 100,568 | $7,971,000 | 312 | |||
06 Loaded work packages
All 68 loaded work packages with owner, contributors, phase, effort and cost. Effort is carried at work-package level only, so nothing is double-counted in the roll-ups above.
| WBS | Work package | Owner | Contributors | Phase | Effort (h) | Cost |
|---|---|---|---|---|---|---|
| 1.1.1 | Tooling concept design — layup mandrel | A. Whitfield | — | Phase 1 | 133 | $11,571 |
| 1.1.2 | Tooling concept design — trim/drill fixture | A. Whitfield | — | Phase 1 | 133 | $11,571 |
| 1.1.3 | Tooling detailed design & drawings — mandrel | A. Whitfield | — | Phase 1 | 163 | $14,142 |
| 1.1.4 | Tooling detailed design & drawings — trim fixture | A. Whitfield | — | Phase 1 | 163 | $14,142 |
| 1.1.4B | Critical Design Review (CDR) — internal walkthrough | M. Osei | D. Okafor | Phase 1 | 222 | $20,475 |
| 1.1.4C | Critical Design Review (CDR) — Meridian engineering sign-off | R. Kessler | D. Okafor | Phase 1 | 222 | $22,142 |
| 1.1.5 | Tooling fabrication — machine shop, mandrel | A. Whitfield | — | Phase 1 | 226 | $19,289 |
| 1.1.6 | Tooling fabrication — machine shop, trim fixture | A. Whitfield | — | Phase 1 | 222 | $19,285 |
| 1.2.1 | Supplier material cert review — prepreg batch data | S. Pham | D. Okafor | Phase 1 | 249 | $20,904 |
| 1.2.2 | Supplier material cert review — fastener hardware | S. Pham | D. Okafor | Phase 1 | 246 | $20,901 |
| 1.2.3 | PPAP sample submission — prepreg | S. Pham | — | Phase 1 | 151 | $14,214 |
| 1.2.4 | PPAP sample submission — fasteners | S. Pham | — | Phase 1 | 147 | $14,210 |
| 1.2.5 | PPAP test & approval — prepreg | S. Pham | — | Phase 1 | 65 | $6,315 |
| 1.2.6 | PPAP test & approval — fasteners | S. Pham | — | Phase 1 | 65 | $6,315 |
| 1.3.1 | Composite layup — ply cutting, S/N 0001 | K. Rutherford | — | Phase 1 | 260 | $17,500 |
| 1.3.2 | Composite layup — hand layup, S/N 0001 | K. Rutherford | — | Phase 1 | 260 | $17,500 |
| 1.3.3 | Composite layup — autoclave cure, S/N 0001 | K. Rutherford | — | Phase 1 | 130 | $8,750 |
| 1.3.4 | Composite layup — trim & drill, S/N 0001 | K. Rutherford | — | Phase 1 | 130 | $8,750 |
| 1.3.5 | NDT ultrasonic scan — S/N 0001 | L. Vance | — | Phase 1 | 624 | $67,500 |
| 1.3.6 | Quality inspection — dimensional layout | B. Solis | — | Phase 1 | 348 | $25,000 |
| 1.3.7 | Quality inspection — visual/cosmetic | B. Solis | — | Phase 1 | 346 | $25,000 |
| 1.3.8 | FAI full dimensional layout — CMM measurement | M. Osei | — | Phase 1 | 521 | $50,001 |
| 1.3.9 | FAI full dimensional layout — hand-tool measurement | M. Osei | — | Phase 1 | 346 | $33,333 |
| 1.3.10 | FAI documentation — AS9102 Form 1 | R. Kessler | — | Phase 1 | 173 | $18,333 |
| 1.3.11 | FAI documentation — AS9102 Form 2/3 | R. Kessler | — | Phase 1 | 173 | $18,333 |
| 1.4.1 | MRB-001 disposition review (edge-trim nonconformance) | R. Kessler | D. Okafor | Phase 1 | 447 | $44,287 |
| 1.4.2 | MRB-001 disposition decision (rework authorized) | R. Kessler | — | Phase 1 | 173 | $18,333 |
| 1.4.3 | Rework composite panel — edge trim re-machining | K. Rutherford | — | Phase 1 | 260 | $17,500 |
| 1.4.4 | FAI re-inspection — dimensional | B. Solis | — | Phase 1 | 346 | $25,000 |
| 1.4.5 | FAI re-inspection — NDT re-scan | L. Vance | — | Phase 1 | 208 | $22,500 |
| 1.5 | Milestone Gate: FAI Accepted | C. Tyrrell | D. Okafor | Phase 1 | 1,064 | $121,904 |
| 2.1 | Production release authorization | C. Tyrrell | D. Marchetti | Phase 2 | 8 | $1,002 |
| 2.2.1 | Panel production — rotation A, batch 1 (S/N 0002-0017) | K. Rutherford | A. Delacroix, C. Nakashima, D. Halvorsen, E. Solberg, J. Packard, J. Whitby +11 more | Phase 2 | 4,051 | $294,901 |
| 2.2.2 | Panel production — rotation A, batch 2 (S/N 0018-0033) | J. Beaumont | A. Delacroix, C. Nakashima, D. Halvorsen, E. Solberg, J. Packard, J. Whitby +11 more | Phase 2 | 5,066 | $368,897 |
| 2.2.3 | Panel production — rotation A, batch 3 (S/N 0034-0050) | K. Rutherford | A. Delacroix, C. Nakashima, D. Halvorsen, E. Solberg, J. Packard, J. Whitby +11 more | Phase 2 | 3,935 | $287,309 |
| 2.2.4 | Panel production — rotation B, batch 1 (S/N 0051-0067) | T. Alvarado | A. Delacroix, C. Nakashima, D. Halvorsen, E. Solberg, J. Packard, J. Whitby +11 more | Phase 2 | 4,040 | $294,872 |
| 2.2.5 | Panel production — rotation B, batch 2 (S/N 0068-0083) | R. Kowalczyk | A. Delacroix, C. Nakashima, D. Halvorsen, E. Solberg, J. Packard, J. Whitby +11 more | Phase 2 | 5,066 | $368,897 |
| 2.2.6 | Panel production — rotation B, batch 3 (S/N 0084-0100) | T. Alvarado | A. Delacroix, C. Nakashima, D. Halvorsen, E. Solberg, J. Packard, J. Whitby +11 more | Phase 2 | 3,935 | $287,309 |
| 2.2.7 | Panel production — rotation C, batch 1 (S/N 0101-0117) | C. Okwuosa | A. Delacroix, C. Nakashima, D. Halvorsen, E. Solberg, J. Packard, J. Whitby +11 more | Phase 2 | 4,040 | $294,872 |
| 2.2.8 | Panel production — rotation C, batch 2 (S/N 0118-0133) | K. Delvecchio | A. Delacroix, C. Nakashima, D. Halvorsen, E. Solberg, J. Packard, J. Whitby +11 more | Phase 2 | 5,066 | $368,897 |
| 2.2.9 | Panel production — rotation C, batch 3 (S/N 0134-0150) | C. Okwuosa | A. Delacroix, C. Nakashima, D. Halvorsen, E. Solberg, J. Packard, J. Whitby +11 more | Phase 2 | 3,935 | $287,309 |
| 2.3.1 | NDT ultrasonic scan — rotation A panels | R. Achebe | L. Vance, R. Kessler | Phase 2 | 2,836 | $262,319 |
| 2.3.2 | NDT ultrasonic scan — rotation B panels | K. Sorensen | L. Vance, R. Kessler | Phase 2 | 2,826 | $262,307 |
| 2.3.3 | NDT ultrasonic scan — rotation C panels | B. Winfield | L. Vance, R. Kessler | Phase 2 | 2,826 | $262,307 |
| 2.3.4 | Dimensional/visual inspection — rotation A & B | B. Solis | R. Kessler | Phase 2 | 2,280 | $181,216 |
| 2.3.5 | Dimensional/visual inspection — rotation C | N. Vasquez | R. Kessler | Phase 2 | 2,280 | $181,216 |
| 2.3.6 | Monthly inspection metrics rollup | P. Larsen | R. Kessler | Phase 2 | 2,480 | $202,307 |
| 2.4.1 | MRB-002 review — surface porosity finding | J. Ferraro | N. Redmond, R. Kessler | Phase 2 | 205 | $22,285 |
| 2.4.2 | MRB-002 disposition (use-as-is) | J. Ferraro | N. Redmond, R. Kessler | Phase 2 | 205 | $22,285 |
| 2.4.3 | MRB-003 review — oversized fastener hole finding | J. Ferraro | N. Redmond, R. Kessler | Phase 2 | 205 | $22,285 |
| 2.4.4 | MRB-003 disposition (rework, oversized fastener) | J. Ferraro | N. Redmond, R. Kessler | Phase 2 | 205 | $22,285 |
| 2.4.5 | MRB-004 review — ply misalignment finding | J. Ferraro | N. Redmond, R. Kessler | Phase 2 | 205 | $22,285 |
| 2.4.6 | MRB-004 disposition (scrap) & root-cause investigation | J. Ferraro | N. Redmond, R. Kessler | Phase 2 | 205 | $22,285 |
| 2.4.7 | MRB-005 review — material traceability gap | J. Ferraro | H. Lindgren, N. Redmond, Q. Whitcomb, R. Kessler | Phase 2 | 223 | $23,507 |
| 2.4.8 | MRB-005 disposition (return-to-supplier) | J. Ferraro | N. Redmond, R. Kessler | Phase 2 | 205 | $22,285 |
| 2.5.1 | Supplier PPAP maintenance — quarterly review Q1 | S. Pham | G. Ochoa, H. Winthrop, M. Ainsley, R. Kessler, T. Winslow, V. Castellanos +1 more | Phase 2 | 1,166 | $85,801 |
| 2.5.2 | Supplier PPAP maintenance — quarterly review Q2 | A. Restrepo | G. Ochoa, H. Winthrop, M. Ainsley, R. Kessler, T. Winslow, V. Castellanos +1 more | Phase 2 | 1,166 | $85,801 |
| 2.5.3 | Supplier PPAP maintenance — quarterly review Q3 | S. Pham | G. Ochoa, H. Winthrop, M. Ainsley, R. Kessler, T. Winslow, V. Castellanos +1 more | Phase 2 | 1,166 | $85,801 |
| 2.5.4 | Supplier PPAP maintenance — quarterly review Q4 | A. Restrepo | G. Ochoa, H. Winthrop, M. Ainsley, R. Kessler, T. Winslow, V. Castellanos +1 more | Phase 2 | 1,166 | $85,801 |
| 2.5.5 | Incoming lot verification — prepreg (ongoing) | W. Fairweather | S. Kandel | Phase 2 | 2,457 | $170,306 |
| 2.5.6 | Incoming lot verification — fasteners (ongoing) | I. Sondheim | S. Kandel | Phase 2 | 2,451 | $170,300 |
| 2.5.7 | Purchase order execution — prepreg replenishment | R. Bianchi | S. Kandel | Phase 2 | 1,541 | $104,184 |
| 2.5.8 | Purchase order execution — fastener replenishment | L. Prescott | S. Kandel | Phase 2 | 1,541 | $104,184 |
| 2.5.9 | Supplier scheduling & delivery coordination | M. Talbot | L. Sheffield, S. Kandel | Phase 2 | 3,487 | $239,609 |
| 2.6 | Preventive maintenance program (layup fixture, post MRB-004) | M. Osei | G. Ochoa, H. Winthrop, M. Ainsley, N. Redmond, R. Kessler, T. Winslow +2 more | Phase 2 | 2,802 | $271,349 |
| 2.7.1 | RAIDD log maintenance & weekly review | D. Okafor | D. Marchetti, G. Ochoa, H. Lindgren, H. Winthrop, M. Ainsley, N. Castillo +4 more | Phase 2 | 11,056 | $875,269 |
| 2.7.2 | Program status report — monthly cadence | C. Tyrrell | D. Marchetti, H. Lindgren, N. Castillo, Q. Whitcomb | Phase 2 | 5,963 | $545,131 |
| 2.8 | Milestone: Program Closeout | C. Tyrrell | D. Marchetti | Phase 2 | 62 | $7,025 |