Direct Job · Hiring
PLC Programmer
Siemens
Details
People Needed7
ShiftDays
Hours/Day10
Hours/Week50
Job Description
Travel Conditions
Hours / Round Trip0 hrs
Trips / Month0
SiemensActivities at Ford Sharonville Transmission Plant - USA: ◼ I created new PLC logic and modified the PLC HMI screen to reduce the processing time of rejected parts by adding new data exchange that stores and displays the reason for each rejected part directly on the PLC HMI. This improvement eliminated the need to manually write down the serial number of every rejected part and then access the Gauge HMI application to obtain the gauge report and identify the rejection reason for each listed serial number. To implement this enhancement, I coordinated with the Gauge personnel to include the status of the tested features in the data exchange, ensuring that all relevant inspection information was available immediately on the PLC HMI. Commissioning the 8F57 PCA Expansion line: o Implementing PLC program improvements and providing customer support until production startup, including adding new PLC logic to solve conveyor issues (parts crashing, releasing parts) and fixing issues with the communication with Gleason stations (OD and RD load Gear), solving the OP250 (Rollscan devices) issues. o Identify the root cause of broken grippers at OP040 and OP045 (Load OD & RD gears on the carrier) reviewing and adjusting the settings of the XRef drive reducing rejected parts in addition to avoid damaging the slide gripper fingers at OP40 & OP45). ▪ Commissioning Palletized Conveyor/line: o Making PLC program improvements and providing customer support until production startup, including adding new PLC logic to solve the RFID issue (biggest problem of the whole line), the Master-Slave Keyence cameras issues and adding new data to get, display and exchange the reason of a part rejected of the “Intra” gauge. o Reviewing and finding the solution to fix the communication issue between the PLC and the IT Server (CPN Switch/HUB problem). o Identifying and solving the cause why the line was not running (Laser Station not running – Servo issue). • Commissioning Contour/Broach/B1034 South line: o Implementing PLC program improvements and providing customer support until production startup. Including adding new PLC logic to fix the Master-Slave Keyence cameras, fixing the change model issues and adjusting PLC logic and setting all the sensors after the Hardness machine. • Support MCA BORE BUILD line: o Identify and solve the FIS communication problem (data exchange) of all the stations on both conveyors (IVB & OVB) as well as extracting and sharing with IT, the descriptions of the fault messages. Activities at Gilman-ES site – Janesville, WI - USA: • Commissioning Battery Cell (TIM, Foam & Epoxy) for Ford CA (Ford Research and innovation center) – Ongoing project. • Support debugging the Washer Load Machine (AP09_0200_0280_Batwings - Ford Livonia) in addition to supporting the machine runoff (by Ford personnel). Activities at ABB USA site – Auburn Hills, MI. - Ford Irapuato machines: • Support running, debugging and solving some issues at OP010.1 MOD-2, OP10.1 MOD3, OP010.2 MOD-2, OP020.2 MOD-2, and OP030.1 MOD-3. • Install PLC program, configure hardware and start running dry cycle of OP010.1 MOD1. • Support debugging OPGE2 Gear Set Assy Line (Vandyke – OP100 & OP110). Activities at Ford Vandyke Plant - USA: • Support debugging OP020.2 MOD3. • Provide production support in the absence of the assigned Controls Engineer. Activities at Ford Irapuato Plant - México: ◼ Support customer in identifying the causes of slow cycle time. After commissioning the OP OP030.1 station, achieving the cycle time requested by the customer, and obtaining early validation (it was the first machine approved in this project) I assisted in identifying and reporting the reason behind the fluctuation of JPHs. The machine cycle was being interrupted frequently due to several factors related to material quality and human resources: ▪ Low- quality subcomponents. Significant time was wasted producing rejected parts and restating production after a bad cycle. The customer eventually assigned personnel from the Materials department and managed this issue, but this was the main problem for some days before Ford took corrective action. ▪ Robot core-release optimization. I proposed changing the way the Robot released the cores in the press station: releasing them as soon as the core aligned with the Shaft (letting gravity complete the final positioning) instead of waiting for the end of the Robot's slow downward movement. This modification was implemented, tested, and approved. ▪ Insufficient personnel at OP030.1 . This machine is very fast, and the assigned operators were constantly rushing. Their responsibilities included loading finished parts, visually inspecting parts, taking measurements and recording them, unloading finished parts, packing, removing rejected parts from the ED40 press, restarting the auto cycle after interruptions removing empty carts, bringing new/full carts from OP020's, and more. ▪ Waiting time for material/subcomponents. I observed frequent shortages of shafts and, at other times, a lack of cats with core stacks ready for OP030.1. ▪ Delayed operator response to empty carts. Sometimes operators did not immediately notice that a cart was empty, causing the continuous cycle to pause while waiting for new core stacks (take out the empty cart, bring/insert a new one). ▪ Blocked unload conveyor. There were short but frequent pauses when the Robot could not unload finished parts because the unload conveyor had no empty pallets available. ▪ Balancer faults. Occasionally, the balancer machine generated faults requiring Ford personnel to manually remove the part, adjust clamps or sensors, and restart the station. This required powering off the equipment and opening the safety door, increasing downtime. ▪ Extended balancing time . In some cases, balancing a part took longer than expected. Support from the Balancer OEM could help, since the OP030.1 cycle time includes the Balancer cycle time. ▪ Data loss in the Balancer Equipment , after part rejection. When the Balancer equipment rejected a part, the operator had to manually remove it. Sometimes the Balancer lost its data for no clear reason, increasing downtime because the operator had to turn off the machine, enter the station, remove the part from the Balancer, and restart the equipment. • Commissioning OP030.1 MOD1 (e-Rotor line), implementing PLC program improvements, providing customer support until full production started. This equipment was the first one to be fully validated by the customer. • Support debugging & solving Promess Press and communication issues at OP020.1 (EtherCAT, zero pos.). • Support debugging and solving OP020 missing data at OP030.1. Activities at Ford Chihuahua Engine Plant - México - Dragon Project – OP170.1A: • Support Installing new Hardware (Scanner DMR-370, etc.) • Debug and solve several OP0170 issues (keys feeder, blowing conditions, key level at Magazine, etc). • Improve OP170 Cycle time (31 sec. to 25 sec.). • Fixing data exchange communication issues (PLC Logic - IT/FIS) at OP170.1A (Aux. waiting, etc.). • Fixing FIS comm. error of OP's 160 (1Fdr, 4D & 2Fdr), OP170 (1CN1, 1Fdr, 2Fdr & 2Fdr), OP220.1 & OP220.3. • Fixing Main Conveyor (S3) blocked (extra part released from decision point of OP220.1 to OP220.3. Activities at Ford Lima Engine Plan t - USA: • Install the new Fasttrack System (Conveyor) into the current conveyor (FCHA area). The installation (new hardware, update PLC program, start up, debugging, etc.) was done and validated one week earlier/faster than planned since there were no issues with the programming nor the hardware thanks to the work done offline at ABB site. • Production Support. Activities at Ford Dearborn Engine Plant - USA: • Close open/pending issues. • Washer machines issues at Block line (MB220_1, MB220_2) and Head line (MH220_1, MH220_2). • Servo Drive issue at OP0070. • Fixing FIS PLC logic of all stations in the washer machines (4). • Update HMI Screen at MB220_2. Activities at Ford Sterling Axle Plant - USA: • Close open/pending issues. • Washer machine issues (D23 – OP020 & OP040). • Onsite Support – D73 Welder (Motor replacement at OP100, Grippers replacement at 0P060, Loctite and Vision System support at OP030, Reject Station support – OP055).Good-to-Have
