Lucas Cato
Saint Peters
Summary
Industrial engineer with a strong record of driving manufacturing process improvements and operational efficiency through strategic, data-informed decision-making. Experienced in streamlining supply chains, optimizing inventory systems, and sustaining existing products and solutions across complex industrial environments. Proven ability to lead resource efficiency initiatives, develop analytical tools for operational improvement, and drive cost savings through data-driven strategies. Skilled in leading cross-functional initiatives and translating complex data into actionable insights that support waste reduction and long-term performance improvements in large-scale manufacturing operations.
Overview
5
5
years of professional experience
Work History
Systems Engineer
The Boeing Company
12.2022 - Current
- Led initiatives to sustain existing aerospace products by optimizing manufacturing processes for repair, refurbishment, and long-term support—reducing waste and extending product life cycles.
- Collaborated with cross-functional teams including engineering, supply chain, and MRO to identify inefficiencies in sustainment workflows, achieving measurable gains in cycle time, throughput, and resource utilization.
- Developed technical enhancements to a critical inventory optimization tool, improving forecasting accuracy and materials planning for repair and maintenance operations.
- Standardized simulation validation processes to ensure accurate modeling of sustainment scenarios, enabling data-driven decision making across manufacturing and support activities.
- Provided mentorship to junior engineers and interns on lean manufacturing, continuous improvement, and sustainment best practices for legacy systems and long-lifecycle products.
- Orchestrated workshops with cross-functional teams to streamline processes, fostering a culture of continuous improvement and shared objectives.
- Interpreted and structured ambiguous data sets to identify sustainment bottlenecks, leading targeted analyses that uncovered root causes and enabled the implementation of solutions that consistently improved efficiency and supported key company performance objectives.
Data Scientist
The Boeing Company
01.2020 - 12.2022
- Spearheaded inventory optimization across indirect manufacturing supply chains, delivering over $15M in annual cost savings by eliminating raw material waste and optimizing resource allocation.
- Designed and implemented advanced forecasting and optimization models aligned with company objectives, increasing free cash flow and improving operational performance by aligning material supply with production demand and enhancing resource efficiency.
- Automated data ingestion and reporting processes to support more agile manufacturing decisions and reduce manual overhead.
- Created simulation models to evaluate the impact of process changes on key performance indicators, including lead time, utilization, and resource availability.
- Participated in research collaborations focused on optimizing global manufacturing logistics and supply chains through system-wide process redesign.
- Developed machine learning models to predict supply chain disruptions, enabling proactive adjustments and reducing potential delays in production.
- Coordinated with cross-functional teams to implement data visualization tools, enhancing transparency and facilitating informed decision-making.
- Maintained comprehensive documentation of data processes and methodologies to ensure compliance and support knowledge sharing across teams.
Supply Chain Intern
The Boeing Company
06.2020 - 12.2020
- Designed and deployed a novel tool for managing inventory during late-stage aircraft production, reducing excess stock and improving final assembly flow.
- Conducted in-depth root cause analysis of material shortages using visual and analytical tools, directly informing process corrections on the factory floor.
- Led development of a standardized project responsibility matrix, improving cross-team coordination and workflow transparency in production support functions.
- Streamlined inventory management processes, resulting in reduced excess stock and enhanced final assembly efficiency.
Education
Master of Science (M.S.) - Industrial Engineering
University of Missouri – Columbia
Columbia, MO12.2020
Bachelor of Science (B.S.) - Industrial Engineering
University of Missouri – Columbia
Columbia, MO12.2019
Skills
- Manufacturing Optimization
- Supply Chain Analytics
- Lean Six Sigma
- Inventory Management
- Forecasting
- Data Analysis
- System Simulation
- Statistical Analysis
- Project Management
- Team Leadership
- Process Optimization
- Root Cause Analysis
- Agile Methodologies
- Data Visualization
- Business Analysis
Awards
Outstanding Industrial and Manufacturing Systems Engineering Student Award, Magna cum laude, Dean’s High Honor Roll
Timeline
Systems Engineer
The Boeing Company
12.2022 - Current
Supply Chain Intern
The Boeing Company
06.2020 - 12.2020
Data Scientist
The Boeing Company
01.2020 - 12.2022
Master of Science (M.S.) - Industrial Engineering
University of Missouri – Columbia
Bachelor of Science (B.S.) - Industrial Engineering
University of Missouri – Columbia
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