John — Controls Engineer

Commissioned to provide PLC/HMI support for three 10R80 Clutch Pack assembly lines. Integrated numerous devices such as Cognex Insight cameras, Datamans & Checkers, Keyence Laser etching hardware and Kinetix 5500/6500 servo drives. Improved ABB Robot handshaking, sequencing & recovery. Third line commissioned for Linamar ON ahead of schedule. Also assisted with Contact Lens machining/packaging lines. Possess Valid TN Visa for work performed while at Client's US facility

Programmed 4 press assembly cells integrating multiple controllers. Cells included standalone presses each with their own PLC control as per the customer. Careful planning of data structure was required in order to coordinate 3 Omron Safety controllers, 3 Omron PLC's, 3 Omron HMI's together with a Motoman material handling robot over Devicenet & Ethernet networks for all cells. Deciphered end-user customer provided standard programming practices. Plant provided code had been modified numerous times by various suppliers making clean implementation more difficult. Functionality and appearance of HMI's was adhered to while improving performance and recovery of cells. Commissioned at F&P OH.

HMI/PLC process system team support for projects involved with the production and handling of iron and steel, oil and gas, food and waste. Siemens PCS7/Win CC programming & visualization for Raw Coal Handling system. Rockwell FT View SE PLC/HMI support for Blast Furnace Hearth Cooling, Stock-House to Blast Furnace Material Feeding, HMI upgrade for Hot Mill Reheat Furnaces and associated Confined Space Gas Monitoring Systems. ABB HMI design and simulation for Hebron Gravity Based Oil Platform.

Commissioned to design the controls for unique machine build challenges. One such project required an operatorfriendly intuitive interface which would simplify the 400+ weld gun parameters to be set-up and adjusted for a network of 8 Lincoln MIG welders. The process needed to weld inner discs to rims, two at a time with the capability of running a continuous or segmented bead with 1, 2 or 4 guns per rim. Collaborated with in-house engineers, leveraging their knowledge of welding. Devised a scheme that allowed easy and quick configuration changes for 10 different vehicle styles. On site at final installation during presentation and smooth run-off for Ford management.

Called on weekly to provide 24-hour maintenance assistance and critical shipment support for over 50 automated machine control cells within the plant. Often commissioned to improve existing automation. For example, analyzed efficiency of two press automation cells running eight Ford "park lock actuators." Collaborated with operators, in-house engineers and tool makers; modified code to smooth out station bottlenecks: improved motion time, changed sequential processes to concurrent etc. Decreased downtime, simplified recovery and reduced cycle times

Hired when installation project was past-due to develop new PAC/HMI code for a Controllogix platform. By conducting a quick self-study, developed a successful interim functional specification illustrating typical operator screens for a crucial project meeting. Project was further complicated by the fact that the automation installation could not experience process downtime. Conducted chemical conveying trials and recipe testing within an 8000 sq. ft. mixing room while production was running. Further, adjusted code to allow new equipment to process stack-up tolerances consistently resulting in a successful buy-off. Produced comprehensive manual and trained new operators.

Assigned to manage the electrical control design for over 15 projects. For example, GM Shanghai commissioned ABB to build and test 8 inner fender hydraulic forming cells at ABB then ship them to China. Traveled to Detroit General Electric Technology Center who were assigned the development of GM Shanghai GE controls specification. Used their support to quickly acquire the necessary tools and product knowledge to expedite the new component purchases, drawing development and machine cell programming. Hired Mandarin translator to assist with the nomenclature for machine labels and screen icons which required both languages. All cells were bought off successfully and on time.