George — Controls Engineer

Deliver follow-ups of electrical design, build, integration, debug and installation of automated assembly systems for various vehicle platforms (BIW, GMAW).

Updated electrical and mechanical blue print and arranged meeting with Structural Engineer for new changes.

Directed and taught plant personnel and vendors on proper operation and maintenance in electrical, mechanical and vision systems with classes and OJT.

Supervised the commission, program, debug, troubleshoot, repair, and maintain Fanuc Robotics Systems including: R-J3iB and R-J3iC controllers, M-710iC, R2000iA, M16, vision, ABB IRC 5 and S4C+ electrical, mechanical, pneumatics and hydraulic systems.

Programmed robots used in resistance welding, material handling and adhesive dispensing applications.

Delivered PLC troubleshooting of assembly lines in RS 5000 19, Guard Logics and RS View Studio for HMI's.

Contracted to Chrysler LLC Corporation to oversee and direct installation of automated welding automotive door assembly systems, such as system commissioning, part runoff and system customer buyoff.

Interfaced with multi-discipline Engineering, Design, and Manufacturing team to optimize welding as part of the manufacturing process.

Installed, configured and debugged signature analysis, repair bay data collection and reporting software.

Delivered programming of Fanuc RJ2 and RJ3 spot welding and MIG welding application.

Designed, implemented and programmed automated paint systems including precision conveyers, robotic paint system and fluid dispensing robots, laser measurement systems, scanners, RF tag identification, rotary indexing tables, vibratory bowl feeders.

Planned and implemented upgrades equipment controlled by AB PLC 5's, ControlLogix 5000, SLC 5/05's & SLC 150's communicating with ControlNet, DeviceNet, DH+ and Ethernet. VFD's, servo's, conveyor's, and vibratory bowl feeder's

03/15-03/17 While engaged at Dunbar Mechanical, Toledo, OH: Provide PLC logic and PanelView screen debug as required. Rollout new technology to keep pace with advances in manufacturing automation, including migration to the Allen-Bradley ControlLogix platform. Deliver follow-ups of electrical design, build, integration, debug and installation of automated assembly systems for various vehicle platforms (BIW, GMAW). Work with counterparts to develop logic and standards for robots HMIs, PLCs and part washing systems. Develop PLC Programs for downtime, part tracking and interface with part marking system. Provide systems for our plants that minimizes downtime by providing troubleshooting assistance to ease restarts from downtime conditions. Correlate and sectionalize existing controls specifications. Worked with the plants for modification specific to their needs. 01/12-03/15 - Control Engineer / FIS While engaged at ICT, Auburn Hills, MI: Contracted to Chrysler LLC Corporation to oversee and direct installation of automated welding automotive door assembly systems, such as system commissioning, part runoff and system customer buyoff. Delivered PLC troubleshooting of assembly lines in RS 5000 19, Guard Logics and RS View Studio for HMI's. Supervised the commission, program, debug, troubleshoot, repair, and maintain Fanuc Robotics Systems including: R-J3iB and R-J3iC controllers, M-710iC, R2000iA, M16, vision, ABB IRC 5 and S4C+ electrical, mechanical, pneumatics and hydraulic systems. Interfaced, troubleshot and debugged production equipment with AB PLC 5's and ControlLogix 5000. Updated make changes and additions to logic. Installed, configured and debugged signature analysis, repair bay data collection and reporting software. Interfaced software to PLC's and SQL database using Ethernet, Interbus and other networks. Verified and updated PLC code addressing. Dealt with PC System, Network and Database Administration, setting up, installing and configuring PC and PLC hardware, UPS and databases, including, Windows Server 2000, SQL 2000 and Sciemetric Software suite. Directed and taught plant personnel and vendors on proper operation and maintenance with classes. Dealt with project management, tooling process, specifications for production equipment and assembly lines, obtaining quotes for production equipment, overseeing installation and support of torque monitoring systems, assembly lines and MES production system. Provided continuous improvement of assembly process through Kaizen techniques and practices. 02/11-11/11 - Automation Engineer While engaged at Racine, WI: Designed, implemented and programmed automated paint systems including precision conveyers, robotic paint system and fluid dispensing robots, laser measurement systems, scanners, RF tag identification, rotary indexing tables, vibratory bowl feeders. Directed and coordinated skilled trades. Worked with Allen Bradley PLC-5s, SLC-500 series.

Programmed and debugged robotics and controls systems. Troubleshot, repaired, and maintained all ABB and Fanuc robotic controllers, vision, dispensing, spot-welding, electrical, mechanical, pneumatics and hydraulic systems. Troubleshot and debugged production equipment with AB PLC 5's, ControlLogix 5000, drives, servos and GUI's PC system and network administration. Installed, configured, set up and debugged operating systems, networks, hardware and software. Directed and taught plant personnel and vendors on proper operation and maintenance in electrical, mechanical and vision systems with classes and OJT. Planned and implemented upgrades equipment controlled by AB PLC 5's, ControlLogix 5000, SLC 5/05's & SLC 150's communicating with ControlNet, DeviceNet, DH+ and Ethernet. VFD's, servo's, conveyor's, and vibratory bowl feeder's.

Set up and programmed 200 Fanuc robots for BIW Line for Ford Motor Company's new Focus Line. Programmed ABB Material Handling and spot welding applications for new car model line Chrysler Belvidere. Delivered programming of Fanuc RJ2 and RJ3 spot welding and MIG welding application. Wrote program, debugged troubleshooting setup of UOP and assisted with robot PLC handshaking. Installed, commissioned, programmed, debugged, troubleshot, repaired, and maintained Fanuc robotics systems including R-J3iB and R-J3iC controllers, M-710iC, R2000iA, and M16, vision, electrical, mechanical, pneumatics and hydraulic systems. Installed, commissioned, troubleshot and debugged production equipment with AB PLC 5's, ControlLogix 5000.

Supervised 33 skill trades including scheduling. Headed and arranged budget meeting to maintain cost saving initiatives. Supervised 103 contactors on a day-to-day basis. Supervised Electrician on maintaining 109 robots in spray booth. Wrote program to change spray pattern and update parameter for film builds. Updated electrical and mechanical blue print and arranged meeting with Structural Engineer for new changes. Trained Electrician and Mill Wright and Pipe Fitter on proper technique in repair of robot system. Performed robot tool calculation for body point and setup of sensors. Gained extensive experience in tool and manufacturing process development with functional expertise in application of geometric dimensioning and tolerance (GD&T).

Supervised installation of material handling robot. Set up and troubleshot hardware and drive for six to seven axis robot. Worked with Electrical and Manufacturing Engineer to set up operation for vision system and paint application. Managed or coordinated welding related projects in a manufacturing environment. Troubleshot welding issues during manufacturing and production. Recommended weld repairs, advised process solutions, developed weld specifications. Interfaced with multi-discipline Engineering, Design, and Manufacturing team to optimize welding as part of the manufacturing process. Set up training for the electrical department to insure the least amount of downtime. Taught millwright on proper change out of gear boxes and dispensing equipment. Rewrote codes for rapid programmer for sealer robot cell. Supervised the installation of robot paint systems and upgrade including programming. Programmed robots used in resistance welding, material handling and adhesive dispensing applications. Integrated and set up robots into automation system applications. Performed robot tool calculation for body point and setup of sensors. Taught a class for Hemming cell setup including advanced TCP to anvil using simulation.

While engaged at Durr Automation, Auburn Hills, MI: Provided technical support for installation of PLC for robotic paint system for the automotive manufacturing company. Also provided 24-hour support commission and runoff for conveyor and plant wide training on different type of equipment. Delivered Allen Bradley control net and flex I/O installation, including software. Troubleshot complex robotic system as in hardware and drive. Installed robotic paint system setup to VMI application using Window NT. Installed robotic arms (mechanical) and changed gearbox when it was damaged. Completed installation of transfer conveyor and robotic gantry system for direct placement on to index table for assembly of power steering component.

While engaged at Zimmerman, Madison Heights, MI: Installed handling systems that used air logic controls shifting centers of gravity. Provided installation support and supervision to our customer's for real-time production situation. Worked with Engineers for precision positioning of handling devices. Managed customer's accounts to insure customer satisfaction also provide onsite training. Carried out installation of automation equipment including pneumatic, mechanical, and electrical for Chrysler, Ford and GM. Modified equipment if customer required unique specifications. Set up function test parameters and calibration install process press for installation of snap ring. Modified PLC program for safety interlock and torque setting on nut runner system. Installation of high-pressure washer to clean contented from part. Programmed robot gripper for pick and place in placement of cam shaft in the assembly of engine blocks.

Instructed Ford Motor Company Mechanics in troubleshooting problems with Automatic Guided Vehicle (AGV). Assisted the Material Handling Department in implementing and launching of the integrated plant wide material transport system. Ran Ethernet wire through the floor to set pathway with a magnet field so the software could interface with computer. Maintained technical specifications for mechanical control system and automation integration.