Calvin — Automation Engineer

Re-engaged by Playtex following an earlier successful assignment; programmed new machinery with servo registration, homing and PackML interfaces for a configuration planned across nine production lines.; Supported electrical/mechanical corrections for a machine configuration intended for replication across nine production lines.

Developed automation for Bosch appliance equipment, including clinching operations and robotic part stacking; supported Tesla multi-station manufacturing and data acquisition.; Retrofitted equipment for new parts, adding servo positions and recipe management.

Installed, debugged and commissioned industrial equipment, including wood-drying kiln systems; supported factory and site acceptance testing for manufacturing customers.

Recruited back by Astec approximately eight years after an earlier engagement that included company-sponsored, instructor-led Siemens training; developed Siemens S7 / TIA Portal V14 controls for Arkansas biomass processing and material handling.; Developed SCL logic for railcar loadout and storage, including automatic material-flow redistribution after bin-screw failures and parameter recovery after restarts. Also supported Astec projects in Georgia.

Led 10 automation technicians relocating and reassembling a Johnson & Johnson Stayfree manufacturing plant from Montreal to Dover, Delaware.; Supported Allen-Bradley controls, Keyence vision and legacy/modern motion systems during equipment relocation and startup.

Supported mixing and process-control operations at a major ice cream manufacturing facility using FactoryTalk Batch and Wonderware.

Integrated Siemens S7 controls, FANUC robots, Cognex vision and RFID for Chrysler torque-converter assembly and Caterpillar diesel-head manufacturing.; Improved Mercedes power-seat testing operations by consolidating stations and coordinating RFID-driven test and fault reporting.

Delivered industrial controls projects using Siemens and Allen-Bradley platforms.

Developed controls for a $16M steel-wheel forming line with Siemens S7 and servo systems, FANUC robotics and industrial drives.

One of four PLC programmers on a $154M Volkswagen Passat underbody project incorporating 144 FANUC robots; developed Siemens PLC/HMI logic to Volkswagen programming standards.; Supported installation and commissioning and remained the final Comau PLC programmer on-site.

Integrated 34 KUKA robots and more than 40 vision/scanning systems on a $350M solar manufacturing expansion using Siemens Step 7, WinCC and Profibus.; Supported MES testing and trained plant personnel in Siemens S7 programming.

Implemented Siemens S7-315 / S7-200 controls, Profibus remote I/O, scanners, testers and drives on a $1.5M manufacturing project in Mexico.; Developed Visual Basic / HMI data interfaces to an Oracle database; supported startup and operator training.

Reinstalled and reprogrammed transferred robotic systems, supported Conair material-delivery installation and trained maintenance personnel.

Contract

Independently developed all PLC and FactoryTalk View v16 HMI software from a blank project for the most robot-intensive cell in a four-cell manufacturing system.; Integrated four ABB robots and 12 servo motors; implemented electronic camming, synchronized master/slave motion, precision positioning, torque monitoring, and automated assembly sequencing.; Integrated GuardLogix safety, ABB OmniCore interfaces, machine vision, EtherNet/IP and IO-Link devices; performed controls commissioning and corrected third-party electrical drawings as needed.

Redeveloped Siemens PLC controls software using TIA Portal V20 and integrated additional CNC machines into an existing manufacturing system.; Worked with Windows-based industrial touchscreen HMI systems on a defense-manufacturing assignment.

Completed Siemens PLC control applications for chassis-to-body marriage and vehicle assembly, integrating Atlas Copco precision fastening with 3D tool-position tracking, torque verification and bolt-level traceability.; Integrated RFID and mainframe production data to support build-to-order vehicle configurations, including engine and paint selections.