Karl Butler M. Eng (Hons)

ILS & RAMS Specialist (Freelance/Contract) | Defence, Rail, Aerospace | ECM II - Maintenance Development | AI-Augmented Engineering Workflows | EU-Based | Director, Integra-Sys Ltd

Malta

About

I help aerospace, defence, rail and transportation organisations avoid making engineering, reliability and supportability commitments they can't realistically deliver. For more than 20 years, I've worked across civil and military programmes helping clients understand the practical implications of their engineering decisions before they become operational, contractual or lifecycle problems. The goal is not more documentation. The goal is better decisions, fewer surprises and more deliverable outcomes. My work typically involves questions such as: • Are the reliability and availability targets realistic? • Will the maintenance concept work in practice? • Have the supportability requirements been properly considered? • Are the lifecycle costs fully understood? • Are there hidden risks in the requirements, assumptions, supplier data or proposed solutions? I specialise in RAMS, ILS, LSA, Lifecycle Engineering and Maintenance Engineering, helping organisations improve asset availability, reduce lifecycle costs, manage programme risk and make better engineering decisions. Areas of expertise include: • RAMS Engineering (Reliability, Availability, Maintainability & Safety) • Integrated Logistics Support (ILS) & Logistics Support Analysis (LSA) • Reliability Engineering & Reliability Prediction • Lifecycle Cost Analysis (LCC) & Level of Repair Analysis (LORA) • Maintenance Engineering, MSG-3 & Maintenance Task Analysis (MTA) • Safety & Hazard Analysis (FTA, FMECA, RCM) • Requirements, Compliance & Interface Management • Asset Management & Supportability Engineering • Spares Optimisation and Maintenance Planning I have supported projects involving Airbus, Eurocopter, Siemens, Stadler, Škoda, Alstom and a range of defence, aerospace and rail programmes across Europe and internationally. I use AI where it helps accelerate analysis, document reviews and information processing, but engineering judgement remains at the centre of every recommendation. Fluent in English and German, with working French and improving Norwegian, I am comfortable working across multinational teams, suppliers, customers and regulatory environments. Available for contract and consulting assignments across Europe and internationally. Independent Consultancy: Integra-Sys Ltd www.logisticsupportanalysis.com

Experience

  • Director/Senior Consultant at Integra-Sys Ltd
    Jan 2016 - Present · 10 yrs 7 mos

    Senior ILS/RAMS Consultant Consultancy delivering ILS/LSA/RAMS support to Aerospace, Defence, Rail and Energy sectors — across both civil and military programmes. Projects typically include maintenance analysis, supportability modelling, spares optimisation, reliability predictions, and lifecycle costing. Core toolsets include MSG-3, LCC, RAMS, ILS/IPS, and supporting documentation across customer and regulatory expectations. I work directly with OEMs, Tier 1 suppliers, and integrators to align technical outputs with project needs, export expectations, and stakeholder compliance — including multi-party, multi-national environments. Fluent in German and comfortable working across English and German-speaking teams — a proven asset on past EU programmes where language alignment accelerated delivery and avoided costly missteps. Flexible engagement models: short-term, long-term, and fixed-scope consultancy across the EU and globally. EU Permanent Resident.

  • Consultant RAMS Engineer – Project Continuation at Skoda Group Austria – via Progressive/sThree
    Jul 2024 - Sep 2024 · 3 mos

    Re-engaged by the client to continue RAMS activities following an initial delivery phase. Supported ongoing integration work on a locomotive fleet project, with continued responsibility for key EN50126 deliverables. Tasks included: - FMECA and FTA updates - Maintainability and Availability Predictions - Validation of RAM requirements - MTA refinement and documentation - Ongoing stakeholder coordination and RAMS support

  • Consultant RAMS Engineer at Skoda Group Austria – via Progressive/sThree
    Dec 2022 - Mar 2024 · 1 yr 4 mos

    RAMS Manager in Rail industry for an integration project on a fleet of locomotives. Responsible for all RAM activities including documentation and analysis, based on EN 50126. Analysis includes, FTA, FMECA, Maintainability Prediction, Availability Prediction, Reliability Prediction. MTA (Maintenance Task Analysis). Determining, validation and verfying the RAM requirements and management.

  • Consultant RAMS & Safety Engineer at BBR / Stadler Rail Braunschweig - SOLCOM GmbH
    Nov 2022 - Jan 2023 · 3 mos

    Analysis of the standard requirements defined by the end customer MBTA for the creation of safety certificates including safety reviews of the safety and reliability-related documents and creation of the SCA (safety compliance assessment) Wayside area.

  • Health and well-being at Career Break
    Oct 2021 - Oct 2022 · 1 yr 1 mo

    Due to COVID and associated effects, a pause was taken.