Stephen — Automation Engineer

I provided Siemens PLC programming support for the both assembly halls at the BMW plant in Greer, SC. The systems we supported included everything from simple station function control to high level vehicle build data handling.

As the Senior Manufacturing Engineer of Automation, I was responsible for all automated machinery and robots in the plant. The plant had Allen-Bradley PLCs, Siemens PLCs, Fanuc robots and Staubli robots. My main responsibility was to keep the machinery running 24 hours per day, 7 days per week. In conjunction with keeping the machinery running, I was also tasked with determining where and how to make automation improvements that would lead to shorter cycle time, better product quality, increased throughput or a better operator experience. For several months I managed the team of Senior Technicians, Technicians and Technician/Operators in an effort to proactively optimize uptime on very old and previously unmaintained machinery as well as educate them in regards to new technology in preparation for new equipment being implemented as part of an expansion project. While I served in this role, our team achieved a dramatic increase in equipment uptime coupled with a dramatic decrease in the number of particulate-inproduct occurrences. I developed several automation concepts with SolidWorks in an effort to evaluate potential opportunities to optimize the manufacturing process. I coded an Android application for inspectors to use for tracking rejects by code. I purchased and configured 24 Fire tablets, installed this application onto the tablets and implemented them at three different locations on the production line. I implemented safety features onto three press machines that had been in production with no safety. This required designing a cage with dual light curtains and dual operator palm touch buttons in addition to completely rewiring the machine and rewriting the PLC code. I designed and built a four camera product inspection table for inspecting the quality and content of printed barcode data and alphanumeric data. I also programmed the Keyence vision system that performed the inspections.

As the Senior Robot Programmer, my responsibilities included managing a team of robot programmers, implementing and maintaining a structured system of programming, implementing and maintaining a reliable program library, and training all robot programmers. I was also responsible for maintaining and upgrading all automation equipment in the plant. I rewrote approximately 90 percent of the existing robot code library in order to maximize robustness, user friendliness and reuse. I then ported the code library from existing Motoman robots to new ABB robots. I was also tasked with developing an internal website on an internal web server to handle numerous forms of information dissemination.

I provided programming support for automation and testing equipment at the Thermo-Fischer plant in Asheville, NC. The project that I worked on involved Siemens PLC programming to implement handheld serial barcode scanners.

As the Senior Automation Engineer, I was responsible for all automation machinery and robots in the plant. The plant had Allen-Bradley PLCs, Siemens PLCs and Fanuc robots. My main responsibility was to keep the machinery running 24 hours per day, 7 days per week. In conjunction with keeping the machinery running, I was also tasked with determining where and how to make automation improvements that would lead to shorter cycle times, better product quality, increased throughput or a better operator experience. I was also responsible for training the plant electricians and technicians, many of whom were unfamiliar with all of the new automation and robots that had been recently installed. I implemented several improvements throughout the plant. These improvements included electrical and mechanical design changes, pneumatic changes and a lot of PLC and robot code changes. I wiped and recoded an entire PLC over a one week shutdown in order to drastically reduce the number of stoppage incidents on a line that experienced 20-30 stoppages each hour.

I programmed PLCs (Siemens) and robots (ABB and Fanuc) for projects at BMW and Drive Automotive. Major Projects BMW (Greer, SC) - I wrote the code for three Pilz safety PLCs and three Siemens PLCs on the new F15/F16 weld assembly lines. I debugged and commissioned the systems. BMW (Greer, SC) - I wrote the robot code (ABB) and the PLC code (Siemens) for an update to a station in the existing F15 motor compartment line. I debugged and commissioned the station as well as provided customer support. BMW (Greere, SC) - I wrote the PLC code (Siemens) for an update of some Bosch nut runners on the final assembly line. I debugged and commissioned the systems and provided customer support. Drive Automotive (Piedmont, SC) - I set up and configured a Fanuc robot for a press loading operation. I wrote the robot code (Fanuc). I debugged and commissioned the robot and provided customer support.

I programmed all types of control devices (I.e., PLCs, HMIs, VFDs, etc.) and designed control circuits for various OEMs and end-users. I debugged my own controls programming and circuitry, as well as that of others. I performed on-site commissioning and provided service support at several locations. Major Projects Lake Erie Tobacco Company (Killbuck, NY) - I wrote the PLC code (Allen-Bradley) and HMI code (Allen-Bradley) for a tobacco pasteurizer. I debugged and commissioned the system and provided customer support. Wild Dunes Golf Course (Wild Dunes, SC) - I wrote the PLC code (CoDeSys) and HMI code (Fuji) for a remote pump station used to transfer water from one irrigation pond to another automatically. This pump station had a local control station and a remote sister station that was conneced via Modbus TCP over a radio link.. I debugged and commissioned the system and provided customer support. Wilburt Plastic Services (Belmont, NC) - I wrote the PLC code (CoDeSys) and the HMI code (CoDeSys) for a plastic liner forming machine. I debugged and commissioned the system and provided customer support.

I programmed all types of devices (I.e., PLCs, HMIs, robots, servomotors, VFDs, etc.) in the construction of various product handling automation cells (e.g., palletizing, depalletizing, laning, machine loading). I debugged my own controls programming and circuitry as well as that of others. I performed on-site commissioning and provided customer support as several locations around the country. Major Projects Tetra Pak (Vancouver, WA) – I wrote the robot code (ABB), the PLC code (Siemens) and the HMI code (Siemens) for a robotic cell that depalletized freshly cut carton blanks and repalletized them in a registered configuration that was conducive to loading downstream machinery. I debugged and commissioned the system and provided customer support. I implemented full fault recovery into the PLC and robot code on this system. This was a big hit with the customer as imperfections in the pallets led to frequent interference issues with the tines on the robot end-of-arm-tooling. When these interference issues occurred and faulted the robot out, no jogging of the robot was required; the operator simply had to press the "home" button and the robot would recover itself to the "home" position. Leinenkugel (Chippewa Falls, WI) – I wrote the robot code (Fanuc), the PLC code (Allen-Bradley) and the HMI code (Allen-Bradley) for a robotic cell that depalletized layers of cartoned empty glass bottles. I debugged and commissioned the system and provided customer support. C&S Wholesale Grocers (Newburgh, NY) - I supported the commissioning of three dual robot multi-sku palletizing cells. I performed necessary debug and implemented resulting modifications and customer requested changes. Coca-Cola (TN, NY, AZ) - I supported the commissioning of several five-robot cells that palletized plastic bottles for shipment. I performed necessary debug and implemented resulting modifications and customer requested changes.

I designed, installed and programmed vision-guided robotic material handling systems. I also designed electrical and fluid power circuits in accordance with customer specifications. I programmed all types of control devices (I.e., PLC, HMI, robot, servomotor, vision system, etc.). I debugged my own controls programming and circuitry, as well as that of others. I performed on-site commissioning and provided service support at several locations. When necessary, I supervised the installation and commissioning process. Major Projects Ford (Kansas City Assembly Plant, Dearborn Truck Plant, Kentucky Truck Plant) – I wrote the robot code (Fanuc TP and Karel) for two Fanuc robots that had a 3-sensor EOAT for checking vehicle paint quality. I assisted with the PLC code (Allen-Bradley) and the HMI code (Allen-Bradley). I debugged and commissioned the cell. Nissan (Decherd, TN) – I integrated a robot cell and conveyor to locate aluminum ingots on pallets and load them into a furnace. I wrote the robot code (Fanuc), the PLC code (Omron) and the HMI code (Omron). I debugged and commissioned the cell. Chrysler (Warren Stamping Plant) – I integrated several vision-guided robots into two separate weld lines. I wrote the robot code (Fanuc) and installed the lighting and cameras. I configured and programmed the PC-based vision systems. I debugged and commissioned the systems and provided customer support. Chrysler (Sterling Stamping Plant) – I integrated a vision-guided robot (ABB) into a weld line. I wrote the robot code and assisted in configuring and programming the PC-based vision system. I debugged and commissioned the system and provided customer support. American Axle and Manufacturing (Detroit) – I integrated two robotically-loaded press stations into carrier assembly lines. I designed the electrical and fluid power circuits. I specified and ordered all electrical and fluid power hardware and devices. I wrote the robot code (Fanuc), the VLC code (Entivity), the servomotor code and the HMI code (Genesis). I configured all of the analog devices that monitored/verified the pressing process. I debugged and commissioned the system and provided customer support. American Axle and Manufacturing (Detroit) – I provided controls programming and troubleshooting support for new machinery being integrated into production and existing machinery running production. This included Fanuc and ABB robot programming, VLC programming (Entivity), PLC programming (Allen-Bradley), HMI programming (Genesis, A- B), servomotor programming, vision system programming/configuration (DVT, Cognex) and electrical and fluid power systems troubleshooting and redesign.

I designed electrical and fluid power circuits in accordance with customer specifications. I specified hardware and devices to be ordered. I programmed all types of control devices (I.e., PLC, HMI, robot, servomotor, vision system, etc.). I debugged my own controls programming and circuitry, as well as that of others. I performed on-site commissioning and provided service support at several locations. When necessary, I supervised the installation and commissioning process. Major Projects Inalfa (Auburn Hills) – I provided controls support for new machinery being integrated into production and existing machinery running production. This included Fanuc and ABB programming, PLC programming (Allen-Bradley), HMI programming (Allen-Bradley RSView), servomotor programming, vision system programming/configuration (DVT, Cognex) and troubleshooting and redesign of electrical circuits and mechanical components.

I designed electrical and fluid power circuits in accordance with customer specifications. I specified hardware and devices to be ordered. I programmed all types of control devices (I.e., PLC, HMI, robot, servomotor, vision system, etc.). I debugged my own controls programming and circuitry, as well as that of others. I performed on-site commissioning and provided service support at several locations. When necessary, I supervised the installation and commissioning process. Major Projects American Axle and Manufacturing (Detroit site) – I integrated several material handling robots (Fanuc and ABB). I wrote the robot code, the PLC code (Allen-Bradley), the VLC code (Entivity) and the HMI code (Genesis and Allen- Bradley). I programmed several servomotors. I designed the electrical and fluid power circuits. I specified and ordered the electrical and fluid power hardware and devices. I debugged and commissioned the system and provided customer support. American Axle and Manufacturing (Detroit site) – I integrated a Rexroth HNC to control a closed-loop hydraulic system to torque the main nut on carrier assemblies. I wrote the VLC code (Entivity), the HMI code (Genesis) and the HNC code. American Axle and Manufacturing (Tonawanda Forging Facility) – I reprogrammed an existing, non-functional ABB robot used to locate steel ingots on a pallet and load them to an upstacker with an electromagnetic EOAT. Visteon (Sterling Axle Plant) – I integrated several material handling robots (ABB and Fanuc). I wrote the robot code, the PLC code (Modicon and Allen-Bradley) and the HMI code (Cutler-Hammer, A-B). I designed the electrical and fluid power circuits. I specified and ordered the controls and fluid power hardware and devices. I debugged and commissioned the cells and provided customer support. Visteon (Sterling Axle Plant) – I integrated six stand-alone press stations into existing axle assembly lines for pressing bearings and seals into axle tubes. I designed the electrical and fluid power circuits. I specified and ordered the electrical and fluid power hardware and devices. I wrote the PLC code (Modicon) and the HMI code (Cutler-Hammer). I configured the analog devices (LRT, force transducers) that monitored/verified the process. I debugged and commissioned the stations and provided customer support. Delphi (Saginaw Steering Plant) – I integrated three rotor runout checking stations into corner assembly lines. I configured the National Instruments equipment that controlled the stations. I wrote the LabView code and debugged the stations. SMW (Sarnia Assembly Plant) – I commissioned a semi-automatic assembly line for corner assemblies. I designed the electrical and fluid power circuits. I specified and ordered the electrical and fluid power hardware and devices. I wrote the PFC code (Wago) and the HMI code (Wago). I programmed several nut torquing devices. I configured several analog devices (LRT, LVDT and force transducers). I created a website that resided on a PC dedicated to the line. I wrote code (HTML, JavaScript) for the website that allowed the user to view all PFCs, the Cognex camera, all mechanical blueprints, all controls schematics and the configuration settings for every device on the line. I debugged the line. Chrysler (Detroit Axle Plant) – I integrated servomotors (to replace existing hydraulic systems) into an existing line that machined power steering pump housings. I programmed the servomotors and redesigned the necessary electrical circuits. I updated the PLC code (Allen-Bradley) with the necessary changes. I debugged and commissioned the system. Chrysler (Detroit Axle Plant) – I integrated a sealant application robot for carrier covers into an axle assembly line. I wrote the robot code (Fanuc) and the PLC code (Telemecanique). I debugged and commissioned the cell and provided customer support. Chrysler (Detroit Axle Plant) – I integrated two hydraulic press stations into an axle assembly line for pressing rotors onto axles. I wrote the PLC code (Telemecanique) and configured the analog devices that monitored and verified the pressing process. I designed the hydraulic circuits and specified the fluid power hardware. I debugged the stations. Chrysler (Detroit Axle Plant) – I created a full internal website (internal) for an axle assembly line that was hosted on an assembly line PC that I set up as a webserver. I wrote code (HTML, JavaScript) that allowed the user to view all PLCs on the line, all mechanical blueprints, all controls schematics, all help files and configuration settings for every device on the line. Chrysler (Kokomo Transmission Plant) – I wrote the robot code (Nachi), the PLC code (Siemens) and the HMI code (Siemens) for a robotic transmission case deburring cell. I also debugged and commissioned the cell.